Disassembly

DISASSEMBLY
1. Disconnect recirculation actuator wiring connector.
2. Remove recirculation housing mounting screws from the HVAC housing.
3. Remove recirculation housing from HVAC housing.

Fig.2 Recirculation Actuator:

4. Remove recirculation actuator mounting screws and remove actuator.

Fig.3 Recirculation Door Gear:

5. Remove recirculation actuator gear mounting screw and remove gear.

Fig.4 Recirculation Door:

6. With a small screw driver, depress recirculation door gear release and remove gear.
7. Tilt the gear end of the recirculation door up and pull the door out of the housing.
8. Remove blower motor wiring connector.
9. Remove blower motor mounting screws and remove motor.

Fig.5 HVAC Harness:

10. Remove HVAC harness connector from the top of the housing.

Fig.6 Evaporator Seal:

11. Remove seal from evaporator coil inlet/outlet.
12. Remove retaining screws from the top of the housing.

Fig.7 HVAC Housing:

13. Separate the top housing from the bottom housing.

Fig.8 Evaporator Temperature Sensor:

14. Remove evaporator temperature sensor.

Fig.9 Evaporator Coil:

15. Lift evaporator out of the bottom housing.

Fig.10 Heater Core:

16. Lift heater core out of the bottom housing.
17. Disconnect blower resistor wiring connector/ ATC blower motor power module wiring connectors.

Fig.11 Resistor Block:

Fig.12 Blower Power Module:

18. Remove blower resistor mounting screws /ATC blower motor power module mounting screws.
19. Remove resistor from the bottom of the housing or ATC module from the side of the housing if equipped.

Fig.13 Lower Heater Duct:

20. Remove lower heater duct screws and remove duct from the bottom housing.

Fig.14 Actuators:

21. Disconnect mode door actuator and blend door actuator wiring connectors.
22. Remove mode door actuator mounting screws and remove actuator.

Fig.15 Mode Actuator Cam:

23. Remove mode door actuator cam.

Fig.16 Defroster Door Lever:

24. Remove heat/defrost door lever mounting screw.

Fig.17 Heat/Defrost Door Assembly:

25. Remove heat/defrost door lever, link and door assembly.

Fig.18 Panel/BI-Level Door Lever:

26. Pull panel/bi-level door lever off door.

Fig.19 Panel/Bi-Level Door Assembly:

27. Remove panel/bi-level door and air deflector from the bottom housing.

Fig.20 Blend Door Actuator:

28. Remove blend door actuator mounting screws and remove actuator.

Fig.21 Blend Door Actuator Cam:

29. Remove blend door actuator cam.

NOTE: The cam must be in the correct position for removal.

Fig.22 Blend Door Release:

30. With a small screw driver, depress blend door release and remove lever and door.
31. Pull other blend door lever off and remove lever and door.