Overhaul
DISASSEMBLYWARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
1. Remove the heater-A/C housing from the vehicle and place it on a work bench.
2. Unplug the vacuum harness connectors from the demist/floor door actuator, the recirculation air door actuator and panel actuator.
3. Disengage the vacuum harness from any routing clips located on the lower half of the heater-A/C housing.
4. Disengage the heater-A/C wire harness connector and the blower motor relay wire harness connector push-in retainers from their mounting holes on the heater-A/C housing.
5. Remove the blower motor and blower wheel unit from the heater-A/C housing.
6. Pull the vacuum supply line and connector through the foam seal on the heater core and evaporator coil tube mounting flange of the heater-A/C housing.
7. Carefully remove the foam seal from the heater core and evaporator coil tube mounting flange of the heater-A/C housing. If the seal is deformed or damaged, it must be replaced.
8. Use a screwdriver to pry off the two snap clips that help secure the upper and lower heater-A/C housing halves to each other.
9. Remove the screws that secure the upper and lower heater-A/C housing halves to each other and those that hold the recirculation housing to the upper housing.
10. Carefully separate the recirculation housing and the upper heater-A/C housing half from the lower half.
ASSEMBLY
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
1. Assemble the upper heater-A/C housing half to the lower half. During assembly, be certain of the following:
a. That each of the mode door pivot shaft ends is properly engaged in its pivot hole.
b. If the unit is equipped with air conditioning, that the evaporator coil tube rubber seal is properly positioned in the grooves in both the upper and lower heater-A/C housing halves.
2. Install the screws and two snap clips that secure the upper and lower heater-A/C housing halves to each other. Tighten the screws to 2.2 Nm (20 in. lbs.).
3. Install the blower motor and wheel unit in the heater-A/C housing.
4. Install the foam seals on the flanges on the heater core and evaporator coil tube mounting flange of the heater-A/C housing and drain tube.
5. Insert the vacuum supply line and connector through the foam seal on the heater core and evaporator coil tube mounting flange of the heater-A/C housing.
6. If the unit is equipped with air conditioning, reinstall the evaporator coil tube clamp. Tighten the mounting screw to 2.2 Nm (20 in. lbs.).
7. Engage the heater-A/C wire harness connector and blower motor relay wire harness connector push-in retainers with their mounting holes in the heater-A/C housing.
8. Engage the vacuum harness to the routing clips and plug in the vacuum harness connector at the floor door actuator and, if the unit is so equipped, at the recirculation air door actuator.