Front HVAC Housing

DISASSEMBLY

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

NOTE: Gasoline model shown in illustrations. HEV model similar.





1. Remove the front HVAC housing (1) and place it on a workbenchFront HVAC Housing Removal.
2. Disconnect the HVAC wire harness (2) from the recirculation door actuator (3).
3. Remove the screws (4) that secure the air inlet housing (5) to the HVAC housing.
4. Remove the air inlet housing from the HVAC housing.
5. If required, remove the recirculation door actuator from the air inlet housingRecirculation Door Actuator - Removal.





6. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2), blend door actuator (3) and the two mode door actuators (4).
7. Remove the evaporator temperature sensor from the top of the HVAC housing (5).
8. Remove the screws that secure the blend door actuator and the mode door actuators to the HVAC housing and remove the actuators.





9. Remove the two actuator couplers (1) from the left end of the HVAC housing (2).





10. If equipped with front dual zone automatic temperature control (ATC) system, disconnect the HVAC wire harness (4) from driver side blend door actuator (2), remove the screws (1) that secure the blend door actuator and cover to the bottom of the HVAC housing (3) and remove the actuator.





11. Carefully remove the foam seal (1) from the flange on the HVAC housing (2). If the seal is deformed or damaged, it must be replaced.
12. Remove the screw (3) that secures the heater core tube retaining bracket (4) to the top of the HVAC housing.
13. Remove the heater core tube retaining bracket from the HVAC housing.





14. Remove the two screws (1) that secure the HVAC housing retaining bracket (2) to the top of the HVAC housing (3).
15. Remove the HVAC housing retaining bracket from the HVAC housing.
16. Remove the two screws (4) that secure the heater core retaining bracket (5) to the top of the HVAC housing.
17. Carefully remove the heater core (6) from the HVAC housing.





18. Disconnect the HVAC wiring harness (1) from the blower motor (2).
19. Remove the blower motor from the HVAC housing (3).
20. Remove the evaporator temperature sensor Front Evaporator Temperature Sensor - Removal.





21. Disconnect the HVAC wiring harness (1) from the blower motor resistor or power module (2), depending on application.
22. If necessary, remove the blower motor resistor or power module, depending on application or Front Blower Motor Power Module - Removal.
23. Remove the HVAC wiring harness from the HVAC housing (3).
24. Remove the screws (4) that secure the two halves of the HVAC housing together.
25. Separate the two halves of the HVAC housing.
26. If necessary, remove the mode-air doors from the upper half of the HVAC housing.





27. Carefully lift the A/C evaporator (1) and insulator (3) out of the top of the HVAC housing (2).






NOTE: Front single zone system shown. Front dual zone system similar.

28. Remove the blend-air doors and linkage (1), mode-air door (2), baffle (3) and the duct plate (4) from the lower half of the HVAC housing (6).
29. If necessary, remove the floor distribution duct (5) from the HVAC housing Floor Distribution Duct - Removal.