Overhaul
DISASSEMBLYNOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, heater core and the mode-air and blend air doors.
1. Remove the HVAC housing from the vehicle and place it on the workbench.
2. Disconnect the HVAC wire harness connectors from the blower motor, blower motor resistor or power module (depending on application), evaporator temperature sensor and each actuator.
HVAC Wire Harness Connector:
3. Remove the two screws that secure the HVAC harness connector to the HVAC housing and remove the HVAC wire harness.
4. Remove the screws that secure the blower motor to the HVAC housing and remove the blower motor.
5. Remove the screws that secure the blower motor resistor or power module (depending on application) to the HVAC housing and remove it from the housing.
6. Remove the screws that secure the air inlet housing to the HVAC housing and remove the air inlet housing.
Recirculation Door Actuator:
7. Remove the three screws that secure the recirculation door actuator to the air inlet housing and remove the actuator.
Recirculation Door Actuator Gear:
8. Remove the screw that secures the recirculation door actuator gear to the air inlet housing and remove the gear.
Recirculation Door Release:
9. Using a small screwdriver, depress the recirculation door gear release and remove the recirculation door gear from the recirculation door shaft.
NOTE: If the seals on the recirculation-air door is deformed or damaged, the air door must be replaced.
10. Tilt the gear end of the recirculation-air door up and pull the door out of the air inlet housing.
NOTE: If either foam seal is deformed or damaged, it must be replaced.
Hvac Housing Seats:
11. Carefully remove the foam seals from the heater core and the evaporator tube mounting flange of the HVAC housing.
HVAC Housing:
12. Remove the screws that secure the upper and lower HVAC housing halves together and separate the housing halves.
Evaporator Temperature Sensor:
13. Using a flat blade pry tool, disengage the locking tab on the access plate of the evaporator temperature sensor. Turn the access plate clockwise one quarter turn and push the access plate inside of the HVAC housing , then orientate the plate in such a way that it can be removed from the housing.
Remove Probe:
14. Remove the evaporator temperature sensor probe from the A/C evaporator and remove the sensor.
A/C Evaporator:
15. Lift the A/C evaporator out of the bottom half of the HVAC housing.
Heater Core:
16. Lift the heater core out of the bottom half of the HVAC housing.
Floor Distribution Duct And Actuators:
17. Remove the screws that secure the floor distribution duct to the bottom half of the HVAC housing and remove the duct.
18. Remove the screws that secure the blend and mode door actuators to the HVAC housing and remove the actuators.
Mode Door Cam:
19. Remove the mode door cam from the HVAC housing.
Floor/Defrost Door Cam:
20. Remove the screw that secures the floor/defrost door cam to the HVAC housing.
Floor/Defrost - Air Door:
21. Remove the floor/defrost door cam, link and door as an assembly.
Panel Door Lever:
22. Remove the panel door lever from the panel air door.
Panel Air Door And Deflector Vane:
23. Remove the panel-air door and air deflector vanes from the bottom half of the HVAC housing.
NOTE: The blend door cam must be in the correct position for removal from the HVAC housing.
Blend Door Cam:
24. Rotate the blend door cam and remove the cam from the HVAC housing.
Blend Door Lever Release:
25. Using a small screw driver, depress blend door lever release and remove the blend door lever and blend-air door from the HVAC housing.
26. Remove the second blend door lever and blend-air door from the HVAC housing.
ASSEMBLY
1. Install the two blend-air doors and levers into the HVAC housing.
NOTE: Rotate the blend door cam until it fully seats into the HVAC housing. The cam followers must be in the correct position to properly install the cam.
Blend Door Cam:
2. Align the blend door cam followers to the blend door cam and install the cam into the HVAC housing.
Blend Door Actuator:
3. Align the blend door actuator spline with the spline in the blend door cam and install the blend door actuator.
4. Install the three screws that secure the blend door actuator to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
NOTE: The center vain of the air deflector must seat into the locating tabs of the bottom HVAC housing.
Air Deflector Vanes:
5. Install the air deflector vanes and panel door into the bottom half of the HVAC housing.
Mode Door Levers:
6. Install the panel door lever to the panel door.
7. Install the floor/defrost door cam, link and door onto the HVAC housing as an assembly.
8. Install the screw that secures the floor/defrost door cam to the HVAC housing. Tighten the screw to 2 N.m (17 in. lbs.).
NOTE: The mode door cam followers must be in the correct position to properly install the cam.
Mode Door Cam:
9. Align the mode door cam followers to the mode door cam and install the cam onto the HVAC housing.
Mode Door Actuator:
10. Align the mode door actuator spline with the spline in the mode door cam and install the mode door actuator.
11. Install the three screws that secure the mode door actuator to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
Floor Distribution Duct:
12. Position the floor distribution duct to the bottom half of the HVAC housing.
13. Install the screws that secure the floor distribution duct to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
NOTE: Make sure that the evaporator drain is clean and unrestricted and that the evaporator insulator is properly installed.
A/C Evaporator:
14. Install the A/C evaporator into the bottom half of the HVAC housing.
NOTE: The A/C evaporator is manufactured with three holes for evaporator temperature sensor probe insertion. Always insert the probe into the uppermost hole.
15. Install the evaporator temperature sensor probe into the A/C evaporator.
16. Install the access plate to the HVAC housing.
Heater Core:
17. Install the heater core into the bottom half of the HVAC housing.
Blend And Mode Door Shafts:
18. Align the blend and mode door shafts with the holes in the HVAC housing and install the top half of the housing to the bottom half of the housing.
19. Install the screws that secure the two halves of the HVAC housing together. Tighten the screws to 2 N.m (17 in. lbs.).
HVAC Housing Seats:
20. Install the foam seals on the heater core and evaporator coil tube mounting flange.
21. Install the recirculation-air door into the air inlet housing.
Recirculation Door Actuator Gear:
22. Install the recirculation door gear onto the recirculation door shaft.
NOTE: The recirculation door actuator gear and door gear must be properly aligned to operate correctly.
23. Align and install the recirculation door actuator gear with the door gear.
24. Install the screw that secure the recirculation door actuator gear to the air inlet housing. Tighten the screw to 2 N.m (17 in. lbs.).
Recirculation Door Actuator:
25. Align the recirculation door actuator spline with the spline in the recirculation door gear and install the recirculation door actuator.
26. Install the three screws that secure the recirculation door actuator to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
27. Install the air inlet housing onto the HVAC housing.
28. Install the screws that secure the air inlet housing to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
29. If removed, install the blower motor resistor or power module (depending on application). Install and tighten the screws to 2 N.m (17 in. lbs.).
30. If removed, install the blower motor. Install and tighten the screws to 2 N.m (17 in. lbs.).
NOTE: Make sure that all HVAC wire harness leads are routed through all HVAC housing wiring retainers.
31. Install the HVAC wire harness onto the HVAC housing.
32. Install the two screws that secure the HVAC wire harness connector to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
33. Connect the HVAC wire harness connectors to the blower motor, blower motor resistor or power module (depending on application), evaporator temperature sensor and each actuator.
34. Install the HVAC housing.