Overhaul

Heater-A/C housing must be removed from vehicle before performing this operation. Refer to Heater-A/C Unit Housing-Removal and Installation.

DISASSEMBLY

Heater-A/C Unit Housing:

1. Place Heater-A/C unit assembly on workbench.

Recirculation Housing Removal:

2. Remove upper recirculation air inlet housing.
3. Front air inlet door and lever is serviced with recirculation housing.

Blower Motor Resister:

4. Remove blower motor wiring at resistor.

Blower Motor:

5. Remove blower motor.

Evaporator Fin Sensor:

6. Using a flat blade pry tool, Pull up on tab at evaporator fin sensor cover. Turn evaporator probe cover clockwise 90 °.
7. Remove evaporator fin sensor cover. Pull evaporator sensor from evaporator.

Housing Clips:

8. Remove clips retaining evaporator housing to heater/distribution housing.

Separate Housings:

9. Separate evaporator housing from heater/distribution housing.

Evaporator Tube Inlet Seal:

10. Remove seal around evaporator tube inlet.

Evaporator Housing Upper Cover:

11. Remove evaporator housing upper cover.

Remove Evaporator From Housing:

12. Lift evaporator out of lower housing.
13. Remove styrofoam seal around evaporator.

Retaining Clips Removal:

14. Remove lower heat/distribution housing clips. Remove housing.

Heater Core Cover:

15. Remove heater core cover.

Heater Core Cover Removal:

16. Slide heater core out of heater housing.

Temperature Door Removal:

17. Press tab in at base of temperature door and release door from lever. Then remove the door.

Mode Door Removal:

18. Press tab in at base of mode door and release door from lever.

Cam Screw Removal:

19. Remove Head/Defrost door cam screw.

Cam And Lever Removal:

20. Lift the cam and mode door lever off of the housing.

Pivot Screw Removal:

21. Remove the Heat/Defrost link pivot screw.
22. Lift the Heat/Defrost link and the door as an assembly. Then separate the link from the door.

ASSEMBLY
To reassemble, reverse the above procedures.