Overhaul

DISASSEMBLY
1. Remove the HVAC housing from the vehicle and place it on a workbench.

HVAC Housing:

2. Disconnect the vacuum harness connectors from the mode and recirculation door actuators.
3. Disengage the vacuum harness from the routing clips located on the HVAC housing.
4. Remove the vacuum harness and grommet from the HVAC housing.
5. Remove the blower motor from the HVAC housing.
6. Carefully remove the foam seals from the heater core and evaporator tapping block flange of the HVAC housing. If either seal is deformed or damaged it must be replaced.
7. Remove the four snap clip retainers that help secure the upper and lower HVAC housing halves together.
8. Remove the screws that secure the upper and lower HVAC housing halves together.
9. Carefully separate the upper HVAC housing from the lower housing.

ASSEMBLY
1. Position the upper HVAC housing half to the lower half. During assembly, be certain of the following.
a. That each of the mode and blend door shafts are properly engaged into the pivot holes in the HVAC housing.
b. That the blower motor venturi ring is properly indexed and installed.
c. If the unit is equipped with air conditioning, that the evaporator seal is properly positioned in the grooves in both the upper and lower HVAC housing halves.
2. Install the screws and four snap clip retainers that secure the upper and lower HVAC housing halves together. Tighten the screws to 2 Nm (17 in. lbs.).
3. Install the blower motor into the HVAC housing.
4. Install the foam seals on the flanges around the heater core and evaporator tapping block flange of the HVAC housing.
5. Install the vacuum supply line and grommet onto the HVAC housing. Check that the vacuum grommet is securely seated into the housing hole flange.
6. Engage the vacuum harness to the routing clips and connect the vacuum harness to the vacuum actuators.