HVAC Housing
HVAC HOUSING
NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator and the mode and blend-air doors.
1. Remove the HVAC housing and place it on a workbench HVAC Housing - Removal.
2. Disconnect the HVAC wiring harness (1) from the recirculation door actuator (2), power module or blower resister (3) (depending on application) and the blower motor (4).
3. Disengage the HVAC wiring harness from the two retaining clips (5) and position the harness out of the way.
NOTE: If the foam seal is deformed or damaged, the seal must be replaced.
4. Remove the foam seal (1) from the front of the HVAC housing (2).
5. If required, remove the two bolts (4) that secure the A/C expansion valve (5) to the evaporator tube tapping block (3) and remove the valve.
6. Remove the three screws (2 and 5) that secure the blower motor and evaporator housing (6) to the HVAC housing (3).
7. Carefully disengage the nine retaining tabs (1 and 4) that secure the blower motor and evaporator housing the HVAC housing.
8. Carefully separate the blower motor and evaporator housing from the HVAC housing
NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.
9. If required, remove the A/C evaporator (1) from the blower motor and evaporator housing (2).
10. If the A/C evaporator is going to be reused, remove and discard the O-ring seals from the evaporator fittings and install plugs into, or tape over the evaporator ports.
11. If equipped with dual zone system, disconnect the HVAC wire harness connector (2) and remove the two screws (4) that secure the blend door actuator (3) to the front of the HVAC housing (1) and remove the actuator.
NOTE: If the foam seal is deformed or damaged, the seal must be replaced.
12. Remove the seal (1) from the flange (2) at the front of the HVAC housing.
13. Remove the two screws (3) that secure the flange (1) to the front of the HVAC housing (2).
14. Carefully disengage the retaining tab that secures the flange to the HVAC housing and remove the flange.
NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.
15. Carefully pull the heater core (4) out of the HVAC housing.
16. Inspect all foam seals and replace as required.
17. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2), blend door actuator (3) and mode door actuators (4 and 6).
18. Remove the HVAC wire harness from the HVAC housing (5).
19. Remove the evaporator temperature sensor from the HVAC housing.
20. Remove the screws that secure the blend and mode door actuators to the HVAC housing and remove the actuators.
NOTE: If the foam seals on top of the HVAC housing are deformed or damaged, they must be replaced.
21. Carefully cut the foam seals (1) along the parting line (5) of the two halves of the HVAC housing (2 and 4).
22. Release the fourteen retaining tabs (3) that secure the two halves of the HVAC housing together and carefully separate the housing.
23. Carefully disengage the mode air doors (1 and 2) from the actuator couplers (5) by pulling the doors straight upward.
NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
24. Remove the mode air doors and the center partition (3), if equipped, from the rear half of the HVAC housing (4).
NOTE: Dual zone system with two blend doors shown. Single zone system with one blend door similar.
25. Carefully disengage the blend air door(s) (2), as equipped, from the actuator coupler(s) (3) by pulling the door(s) straight upward.
NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
26. Remove the blend air door(s) from the HVAC housing (1).
NOTE: Typical actuator coupler shown.
27. Remove the actuator coupler(s) (1) from the HVAC housing (2), as required. Carefully release the three retaining tabs (3) on each actuator coupler from the inside surface of the HVAC housing and push the coupler(s) out of the housing.