Bench Overhaul

1. Remove temperature cable housing from retainer clip and remove cable eyelet from temperature door lever.
2. Remove electrical connectors to control head and remove control head.




3. Remove blower motor housing screws and release both tabs and remove housing.
4. Lift blower motor upward and disconnect blower motor electrical connector by squeezing bottom of connector and pulling downward.




5. Remove HVAC module electrical harness connectors from mode actuator, blower resistor card, and recirculation actuator. Pull blower motor harness grommet out of case.




6. Remove harness screw at mode actuator on case.
7. Remove harness main connector by sliding towards left.




8. Remove connector duct screw and pull connector duct downward to remove.




9. Remove mode actuator screws and remove actuator.




10. Remove mode cam.




11. Remove primary lever screws and remove primary levers.




12. Pry sub-levers off with a flat blade screwdriver.




13. Remove recirculation actuator screws and remove actuator.




14. Remove blower motor resistor card screws and remove.




15. Remove lower insulator by stretching past two hooks on bottom case and pulling forward.




16. Open heater core pipe connector collars and remove. Clamps may need to be rotated to gain access to retaining tab. Pull heater core pipes out of heater core and through HVAC module case to remove.




17. Remove heater core retainer and slide heater core out of module.




18. Turn module upside down and remove lower case screws and remove lower case.
19. Remove evaporator, TXV and seal by lifting straight up. Remove TXV and seal from evaporator.




20. Turn module right side up and use a razor blade to cut defroster/vent seal and blower motor opening seal at center line.




21. Release recirculation door connecting rod from retainer. Remove rod from small door lever and remove. Remove large and small recirculation doors.

IMPORTANT: There are two clips and nine screws. Two screws are located in deep cavities.




22. Remove case half retainer clips and screws.

NOTE: One screw is located at the center of case.




23. With case laying on left side, lift right side straight up to split module.




24. Remove mode and temperature doors.