Overhaul

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

Defrost, Floor, And Panel/Demist Door Vacuum Actuators - Typical:

2. Unplug the vacuum harness connectors from the panel/demist door actuator, defrost door actuator, floor door actuator and recirculation door actuator (if equipped) .
3. Disengage the vacuum harness from any routing clips located on the lower half of the HVAC housing.
4. Disengage the HVAC wire harness connector and the blower motor relay wire harness connector push-in retainers from their mounting holes in the HVAC housing.
5. Remove the blower motor from the HVAC housing.

HVAC Housing Disassembly - Typical:

6. Pull the vacuum supply line and connector through the foam seal on the heater core and evaporator coil tube mounting flange .
7. Remove the screw that secures the evaporator tube clamp and remove the clamp from the evaporator tubes.
8. Carefully remove the foam seal from the heater core and evaporator coil tubes and mounting flange of the HVAC housing. If the seal is deformed or damaged, it must be replaced.
9. Remove the two snap clips that help secure the upper and lower HVAC housing halves together.
10. Remove the screws that secure the upper and lower HVAC housing halves to each other and those that hold the recirculation housing to the upper housing.
11. Carefully separate the recirculation housing and the upper HVAC housing half from the lower housing.

ASSEMBLY
1. Position the upper HVAC housing to the lower housing. 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 HVAC housing halves.
2. Install the screws that secure the upper and lower HVAC housing halves to each other and those that hold the recirculation housing to the upper housing. Tighten the screws to 2.2 Nm (20 in. lbs.).
3. Install the two snap clips that help secure the upper and lower HVAC housing halves together.
4. Install the foam seals on the heater core and evaporator coil tubes and mounting flange of the HVAC housing.
5. If the unit is equipped with air conditioning, reinstall the evaporator tube clamp and retaining screw. Tighten the screw to 2.2 Nm (20 in. lbs.).
6. Insert the vacuum supply line and connector through the foam seal on the heater core and evaporator coil tube mounting flange.
7. Install the blower motor.
8. Engage the HVAC wire harness connector and blower motor relay wire harness connector push-in retainers in the mounting holes of the HVAC housing.
9. Engage the vacuum harness to the routing clips located on the lower half of the HVAC housing.
10. Plug in the vacuum harness connectors to the panel/demist door actuator, defrost door actuator, floor door actuator and recirculation door actuator (if equipped).