Evaporator Housing Disassembly and Assembly

NOTE: Heater-A/C unit housing must be removed from vehicle before performing this operation. Refer to Evaporator Case Replacement. Evaporator Housing Removal and Installation

DISASSEMBLE
1. Place heater-A/C unit assembly on workbench.
2. Pull back on retaining tabs and remove heater core from housing.

Recirculation Door Actuator Wiring:

Recirculation Door Actuator:

3. Remove recirculation door actuator wiring. Remove actuator from recirculation housing.

Lower Distribution Housing:

Mode Door Actuator:

4. Remove lower distribution housing. Remove mode door actuator.

Blend Air Door Actuator:

5. Remove blend air door actuator.

Recirculation Housing:

6. Remove recirculation housing screws and clip.

Blower Motor Wiring:

7. Remove blower motor wiring at resistor.

Wiring Grommet:

8. Squeeze blower motor wiring grommet and push grommet through blower motor cover.

Blower Motor Cover:

9. Remove blower motor cover.

Blower Motor:

10. Remove screws at blower motor mounts. Remove motor.

Blower Motor Resistor:

11. Remove blower motor resistor.
12. Remove wiring at evaporator temperature probe.

Evaporator Probe:

13. Using a screwdriver, pry up on tab at evaporator probe. Twist probe counterclockwise and push tab into the housing.

Evaporator Probe:

14. Pull the evaporator probe needle out of the evaporator fins. Remove the evaporator probe through the opening at the blower motor housing.

Vent Door Seal:

15. Remove vent door seal from housing.

Evaporator Seal:

16. Remove evaporator seal from housing.

A/C Housing Screws:

17. Remove upper housing screws and clips.

Lower Housing:

18. Separate upper housing from lower housing.

Evaporator:

19. Remove evaporator assembly from lower housing.

Blend Air Door:

20. Remove blend air door from lower housing.

Vent Door Retaining Tab:

Vent Door Removal:

21. Using a flat blade screwdriver, pinch in the retaining tab at the base of the vent door. Pull up on door and remove from housing.

Mode Door Actuating Cam:

Cam Removal:

22. Remove mode door actuating cam.

Defrost Door Actuator Arm Screw:

23. Remove screw at defrost door actuating arm. Remove defrost door link from arm.

Defrost Door Arm:

24. Remove defrost door arm from lower housing.

Defrost Door And Link:

25. Remove link and defrost door from housing.

Link Removal From Door:

26. Remove defrost door link from door.

Vent Door Actuator Arm:

27.Remove vent door actuating arm from lower housing.

ASSEMBLE
1. Install vent door actuating arm to lower housing.
2. Install defrost door link to defrost door.

Defrost Door And Link:

3. Install door and link into A/C housing.

Defrost Door Actuator Arm Screw:

4. Install defrost door actuating arm and retaining screw at housing.
5. Install defrost door link to actuating arm.

Cam Removal:

6. Line up the slots to the pegs on the mode door cam. Install the mode door cam.
7. Turn housing over and snap in the vent door to the vent door arm.

Blend Air Door:

8. Install blend-air door in the housing.
9. Install evaporator into the lower housing.
10. Install upper housing onto lower housing.

A/C Housing Screws:

11. Install screws to retain the upper housing to the lower housing.
12. Install evaporator and vent door seals onto the A/C housing.

Evaporator Probe:

13. Install evaporator probe assembly into the housing. Insert probe needle into evaporator.
14. Position the evaporator probe assembly at the housing face. Twist assembly clockwise to lock tab into slot on housing face.
15. Install wiring at evaporator temperature probe.
16. Install blower motor resistor.

Blower Motor:

17. Install blower motor into housing. Install blower motor mounting screws.

Blower Motor Cover:

18. Thread the blower motor wiring through the blower motor cover. Install the blower motor cover.

Wiring Grommet:

19. Seat blower motor wiring grommet at blower motor cover.
20. Install blower motor wiring to the blower motor resistor.

Recirculation Housing:

21. Position recirculation housing to A/C housing. Install retaining screws and clip.

Blend Air Door Actuator:

22. Install blend-air door actuator.

Mode Door Actuator:

23. Install mode door actuator.

Lower Distribution Housing:

24. Install lower distribution housing.

Recirculation Door Actuator:

25. Install recirculation door actuator and wiring.

Heater Core Removal:

26. Install heater core into A/C housing.

Heater Core:

27. Retain core with screws.

INSTALLATION
1. Installation of evaporator case is the reverse of removal.
2. Evacuate recharge and test a/c system.