Overhaul
DISASSEMBLY1. Disconnect recirculation actuator wiring connector.
2. Remove recirculation housing mounting screws from the HVAC housing.
3. Remove recirculation housing from HVAC housing.
Recirculation Actuator:
4. Remove recirculation actuator mounting screws and remove actuator.
Recirculation Door Gear:
5. Remove recirculation actuator gear mounting screw and remove gear.
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.
HVAC Harness:
10. Remove HVAC harness connector from the top of the housing.
Evaporator Housing Seals:
11. Remove seal from evaporator coil inlet/outlet.
12. Remove retaining screws from the top of the housing.
HVAC Housing - New H-Valve Connector:
13. Separate the top housing from the bottom housing.
Evaporator Temperature Sensor:
14. Remove evaporator temperature sensor.
Evaporator Coil (New) H-Valve:
15. Lift evaporator out of the bottom housing.
Heater Core:
16. Lift heater core out of the bottom housing.
17. Disconnect blower resistor wiring connector/ATC blower motor power module wiring connectors.
Resistor Block:
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.
Lower Heater Duct:
20. Remove lower heater duct screws and remove duct from the bottom housing.
Actuators:
21. Disconnect mode door actuator and blend door actuator wiring connectors.
22. Remove mode door actuator mounting screws and remove actuator.
Mode Actuator Cam:
23. Remove mode door actuator cam.
Defroster Door Lever:
24. Remove heat/defrost door lever mounting screw.
Heat/Defrost Door Assembly:
25. Remove heat/defrost door lever, link and door assembly.
Panel/Bi-level Door Lever:
26. Pull panel/bi-level door lever off door.
Panel/Bi-level Door Assembly:
27. Remove panel/bi-level door and air deflector from the bottom housing.
Blend Door Actuator:
28. Remove blend door actuator mounting screws and remove actuator.
29. Remove blend door actuator cam.
Blend Door Actuator Cam:
NOTE:The cam must be in the correct position for removal.
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
ASSEMBLY
1. Install blend doors and levers into the bottom housing.
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.
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.
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.
Mode Door Levers:
7. Install heat/defrost door, link and lever.
Mode Cam Followers:
8. Align mode door cam with lever followers and install cam.
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.
Blower Motor:
11. Install blower motor into the bottom housing.
12. Install blower mounting screws and plug in wiring connector.
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.
Lower Heater Duct:
15. Install lower heat duct and mounting screws.
Evaporator Coil (new) H-Valve:
16. Install evaporator coil into the bottom housing.
17. Install evaporator temperature sensor.
Heater Core:
18. Install heater core into the bottom housing.
Door Shafts:
19. Install and align the top of the housing with the door shafts.
20. Install top housing mounting screws.
Evaporator Housing Seals:
21. Install evaporator inlet/outlet seal.
22. Install recirculation door into the recirculation housing.
23. Install recirculation door gear onto the door shaft.
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.
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.