Assembly

ASSEMBLY
1. Install blend doors and levers into the bottom housing.

Fig.23 Blend Cam Followers:

2. Align blend actuator cam and lever followers and install cam.

NOTE: Rotate cam until it drops into the housing. The cam must be in the correct position to install.

Fig.24 Blend Actuator Spline:

3. Align blend actuator spline with cam spline and install actuator.
4. Install blend actuator mounting screws and plug in wiring connector.

Fig.25 Panel/BI-Level Door And Air Deflector:

5. Install panel/bi-level door and air deflector into the housing.

NOTE: Center vain of the air deflector must seat in the bottom housing locating tabs.

6. Install panel/bi-level door lever into bottom of the door shaft.

Fig.26 Mode Door Levers:

7. Install heat/defrost door, link and lever.

Fig.27 Mode Cam Followers:

8. Align mode door cam with lever followers and install cam.

Fig.28 Mode Actuator Spline:

9. Align mode actuator spline with cam spline and install actuator.
10. Install mode actuator mounting screws and plug in wiring connector.

Fig.29 Blower Motor:

11. Install blower motor into the bottom housing.
12. Install blower mounting screws and plug in wiring connector.

Fig.30 Resistor Block:

13. Install blower resistor into the bottom of the housing or ATC blower motor power onto the side of the housing.
14. Install blower resistor/blower motor power module mounting screws and plug in wiring connector/connectors.

Fig.31 Lower Heater Duct:

15. Install lower heat duct and mounting screws.

Fig.32 Evaporator Coil:

16. Install evaporator coil into the bottom housing.
17. Install evaporator temperature sensor.

Fig.33 Heater Core:

18. Install heater core into the bottom housing.

Fig.34 Door Shafts:

19. Install and align the top of the housing with the door shafts.
20. Install top housing mounting screws.

Fig.35 Evaporator Seal:

21. Install evaporator inlet/outlet seal.
22. Install recirculation door into the recirculation housing.
23. Install recirculation door gear onto the door shaft.

Fig.36 Recirculation Door Gear:

24. Align and install recirculation actuator gear with the door gear and install retaining screw.

NOTE: Gears must be align properly to operate.

Fig.37 Recirculation Actuator:

25. Align recirculation actuator spline with the actuator gear spline and install actuator.
26. Install recirculation actuator mounting screws.
27. Install recirculation housing onto the top housing and install mounting screws.
28. Plug in recirculation actuator wiring connector.