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HVAC Housing







HVAC HOUSING

NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, evaporator temperature sensor, mode-air and blend-air doors.





1. Remove the HVAC housing assembly and place it on a workbench HVAC Housing - Removal and Installation .
2. Disconnect the HVAC wire harness connectors from the mode door actuators (1), blend door actuators (2) and the recirculation door actuator (3).
3. Remove the screws that secure the mode door actuators and the blend door actuators to the HVAC housing (5) and remove the actuators.
4. Remove the screws that secure the recirculation door actuator to the air inlet housing (4) and remove the actuator.




5. Disconnect the wire harness connectors (1 and 3) from the blower motor resistor (7) and the blower motor (2).
6. Remove the screws (4) that secure the blower motor to the HVAC housing (5) and remove the blower motor.
7. Remove the screws (6) that secure the blower motor resistor to the HVAC housing and remove the resistor.




8. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) and remove the wiring harness and the sensor from the HVAC housing (4).
9. Remove the air inlet housing (3) from the HVAC housing HVAC Housing - Removal and Installation .




10. Remove the two screws (1) that secure the panel/floor door outlet (2) to the top of the HVAC housing (4).

NOTE: If the foam seal on the panel/floor door outlet is deformed or damaged, it must be replaced.

11. Release the two retaining tabs (3) that secure the panel/floor door outlet to the front of the HVAC housing and remove the door outlet.




12. Remove the three screws (1) that secure the panel/floor door assembly (2) to the top of the HVAC housing (3) and remove the door assembly.




13. To remove the panel/floor-air doors (1) from the panel/floor door plate (2), first carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the door plate and pull the actuator coupler out of the pivot shaft of the panel/floor-air doors.

NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced.

14. Remove the panel/floor-air doors from the panel/floor door plate.




NOTE: If the foam seal for the heater core tubes is deformed or damaged, the seal must be replaced.

15. Remove the foam seal from the heater core tubes.
16. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3).
17. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket.
18. Carefully pull the heater core out of the front of the HVAC housing.
19. Inspect all heater core foam seals and replace as required.




20. Remove the screws (3) that secure the floor distribution duct (1) to the bottom of the HVAC housing (2).
21. Remove the floor distribution duct from the HVAC housing.




22. Carefully disconnect the linkage rod (1) from the two blend-air door levers (2) located on the back of the HVAC housing (3).

NOTE: If the foam seal for the evaporator condensate drain tube is deformed or damaged, the seal must be replaced.

23. Remove the foam seal (4) from the evaporator condensate drain tube (5).
24. Remove the fifteen screws (6) that secure the upper and lower HVAC housing halves together and separate the housing halves.




25. Release the three retaining tabs (1) that secure the lower blend door assembly (2) to the lower half of the HVAC housing (3) and remove the door assembly.
26. Release the three retaining tabs that secure the upper blend door assembly to the upper half of the HVAC housing and remove the door assembly.




27. To remove the blend-air doors (1) from each blend door plate (2), first carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the door plate being serviced and pull the actuator coupler out of the pivot shaft of the blend-air doors.

NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced.

28. Remove the blend-air doors from the blend door plates.




29. Remove the defroster-air doors (1) from the lower half of the HVAC housing (2) by carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the housing and pull the actuator coupler out of the pivot shaft of the defroster-air doors.

NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced.

30. Remove the defroster-air doors from the HVAC housing.




NOTE: If the foam seal for the A/C evaporator tubes is deformed or damaged, the seal must be replaced.

31. Remove the foam seal (1) from around the tubes of the A/C evaporator (3).
32. Carefully lift the A/C evaporator out of the upper half of the HVAC housing (2).
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