Overhaul

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

The heater-A/C unit need not be disassembled to replace the heater core. Refer to: "Heater Core : Service and Repair" Service and Repair

DISASSEMBLY

Heater - A/C Unit:

Mode Motor Linkage:

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

Mode Motor:

2. Remove A/C mode motor.

Recirculation Air Inlet:

Recirculation Housing Removal:

3. Remove upper recirculation air inlet housing.

Rear Y-Cam Release:

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

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.

Rear Air Inlet Door:

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

Blower Motor Wiring:

12. Remove blower motor wiring at resistor.

Blower Motor:

13. Remove blower motor.

Evaporator Probe:

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

Evaporator Probe Needle:

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

Blower Motor Resistor:

16. Remove blower motor resistor.

Housing Clips:

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

Separate Housings:

18. Separate evaporator housing from heater/distribution housing.

Evaporator Tube Inlet Seal:

19. Remove seal around evaporator tube inlet.

Evaporator Housing Upper Cover:

20. Remove evaporator housing upper cover.

Remove Evaporator From Housing:

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

Lower Floor Distribution Housing:

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

Heater Core Cover:

Heater Core Cover Removal:

24. Remove heater core cover.

Slide Out Core:

25. Slide heater core out of heater housing.

Temperature Door Lever Link:

26. Remove temperature door lever link retaining screw.

Temperature Door Lever Link Removal:

27. Remove temperature door lever link.

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.

Align Slots:

Remove Lever Link:

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

Mode Motor Cam:

Mode Motor Cam Removal:

30. Remove mode motor cam from housing.

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.

Panel Door Lever Link:

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

Defrost Door Lever Link:

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

Front And Rear Housing Halves:

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

Defrost Door Removal:

37. Remove defrost door from housing.

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.

Floor Door Removal:

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

ASSEMBLY
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.