Heater-A/C Housing Disassembly and Assembly

Fig 74 Heater-A/C Unit:

Fig 75 Mode Motor Linkage:

UNIT HOUSING RECONDITION

NOTE: Heater-A/C housing must be removed from vehicle before performing this operation. The heater a/c unit need not be disassembled to replace the heater core. Refer to Heater Core replacement.

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

Fig 76 Mode Motor:

2. Remove A/C mode motor.

Fig 77 Recirculation Air Inlet:

Fig 78 Recirculation Housing Removal:

3. Remove upper recirculation air inlet housing.

Fig 79 Rear Y-Cam Release:

4. From inside of air inlet, depress release tang on rear inlet door.

Fig 80 Rear Y-Cam Actuator:

5. Remove rear Y-cam actuator lever.
6. Turn front toggle lever until it lines up with slots on housing.
7. Pull straight up on toggle lever and slide toggle lever from underneath front actuator lever.
8. Remove front toggle lever.
9. Remove Y-cam rear lever.

Fig 81 Rear Air Inlet Door:

10. Unsnap and remove rear air inlet door.
11. Front air inlet door and lever is serviced with recirculation housing.

Fig 82 Blower Motor Wiring:

12. Remove blower motor wiring at resistor.

Fig 83 Blower Motor:

13. Remove blower motor.

Fig 84 Evaporator Probe:

14. Using a flat blade pry tool, Pull up on tab at evaporator probe cover. turn evaporator probe cover clockwise 90°.

Fig 85 Evaporator Probe Needle:

15. Remove evaporator probe cover. Pull evaporator needle from evaporator.

Fig 86 Blower Motor Resistor:

16. Remove blower motor resistor.

Fig 87 Housing Clips:

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

Fig 88 Separate Housings:

18. Separate evaporator housing from heater/distribution housing.

Fig 89 Evaporator Tube Inlet Seal:

19. Remove seal around evaporator tube inlet.

Fig 90 Evaporator Housing Upper Cover:

20. Remove evaporator housing upper cover.

Fig 91 Remove Evaporator From Housing:

21. Lift evaporator out of lower housing.
22. Remove styrofoam seal around evaporator.

Fig 92 Lower Floor Distribution Housing:

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

Fig 93 Heater Core Cover:

Fig 94 Heater Core Cover Removal:

24. Remove heater core cover.

Fig 95 Slide Out Core:

25. Slide heater core out of heater housing.

Fig 96 Temperature Door Lever Link:

26. Remove temperature door lever link retaining screw.

Fig 97 Temperature Door Lever Link Removal:

27. Remove temperature door lever link.

Fig 98 Floor Door Gear:

28. From the panel door air opening, using a long thin screwdriver, push in clip for floor door gear. Remove floor door gear.

Fig 99 Align Slots:

Fig 100 Remove Lever Link:

29. Turn floor door lever link until it aligns with slots cut into it. Remove floor door lever link.

Fig 101 Mode Motor Cam:

Fig 102 Mode Motor Cam Removal:

30. Remove mode motor cam from housing.

Fig 103 Panel Door Gear Release:

31. From panel door access, using a long thin screwdriver, push in release tang on panel door gear.
32. Remove panel door gear from housing.

Fig 104 Panel Door Lever Link:

33. Line up slots on panel door lever link. Remove panel door lever link from housing.

Fig 105 Defrost Door Lever Link:

34. Unsnap defrost door lever link from housing.
35. Remove defrost door seal from housing.

Fig 106 Front And Rear Housing Halves:

36. Remove A/C housing rear cover half from front half.

Fig 107 Defrost Door Removal:

37. Remove defrost door from housing.

Fig 108 Temperature Control Door Removal:

38. Depress retaining clip at temperature control door, remove temperature control door.
39. Unsnap panel door from rear half of housing. Remove door from housing.

Fig 109 Floor Door Removal:

40. Unsnap floor door from front half of housing. Remove door from housing.

ASSEMBLE
1. Install floor, panel, temperature, and defrost doors in housings.
2. Position front A/C housing half to rear half. Install retaining screws.
3. Install defrost door seal.
4. Snap defrost door lever link to door.
5. Install panel door lever link. Install panel door lever gear.
6. Install mode motor cam.
7. Install floor door lever link.
8. Install floor door lever gear.
9. Install temperature door lever gear.
10. Install temperature door lever link.
11. Slide heater core into housing. Install cover.
12. Install lower distribution housing and clips.
13. Install styrofoam to evaporator. Install evaporator into the evaporator housing.
14. Install upper cover to evaporator housing.
15. Install seal around evaporator tube inlet.
16. Install evaporator probe into evaporator and housing.
17. Install blower motor and resistor.
18. Install air inlet housing to evaporator housing.
19. Install evaporator housing to heat/distribution housing.
20. Install mode motor.