HVAC Housing
DISASSEMBLYNOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, mode-air and blend-air doors.
1. Remove the HVAC housing (1) and place it on a workbench.
2. Disconnect the HVAC wire harness (2) from the mode door actuators (3 and 4) located on the driver side end of the HVAC housing.
3. Remove the screws (5) that secure the mode door actuators to the HVAC housing and remove the actuators.
4. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) and the blend door actuator (3) located on the top of the HVAC housing (4).
5. Remove the screws (5) that secure the blend door actuator to the HVAC housing and remove the actuator.
6. Remove the evaporator temperature sensor from the HVAC housing.
7. Remove the lever and linkage rod (1) from the blend door pivot shaft (2) located on the top of the HVAC housing (3).
8. Carefully disconnect the lever and linkage rod from the blend door pivot lever (4).
9. Disconnect the HVAC wire harness (1) from the blower motor resistor (2), recirculation door actuator (3), and the blower motor (4).
10. Remove the three screws (5) that secure the blower motor to the HVAC housing (6) and remove the blower motor.
11. Remove the HVAC wiring harness from the HVAC housing.
12. Remove the four screws (1) that secure the air inlet housing (2) to the top of the HVAC housing (3) and remove the air inlet housing.
NOTE: If the foam seal on the air inlet housing is deformed or damaged, it must be replaced.
13. If required, disassemble the air inlet housing.
NOTE: If the foam seal on the panel/defrost outlet is deformed or damaged, it must be replaced.
14. Remove the foam seal (1) from the panel/defrost outlet (2) located on the top of the HVAC housing (3).
15. Remove the six screws (1) that secure the panel/defrost outlet (2) to the top of the HVAC housing (3) and remove the outlet.
NOTE: If the seal on the air door is deformed or damaged, the air door must be replaced.
16. Remove the panel-air door (1) from the opening located at the top of the HVAC housing (2).
17. Remove the three screws (1) that secure the floor distribution duct (2) to the bottom of the HVAC housing (3) and remove the duct.
NOTE: If any of the foam seals are deformed or damaged, the seal(s) must be replaced.
18. Remove the three foam seals (1 , 2 and 3) from the HVAC housing (4).
19. Remove the two metal clips (5) eleven screws (6) that secure the upper and lower HVAC housing halves together and separate the housing halves.
NOTE: If the foam seal around the heater core is deformed or damaged, the seal must be replaced.
20. Carefully lift the heater core (1) out of the lower half of the HVAC housing (2).
NOTE: If the rubber flange around the heater core tubes is deformed or damaged, the flange must be replaced.
21. If required, remove the rubber flange (3) from around the heater core tubes (4).
22. Carefully lift the A/C evaporator (1) out of the lower half of the HVAC housing (2).
NOTE: If the rubber flange around the evaporator tubes is deformed or damaged, the flange must be replaced.
23. If required, remove the rubber flange (3) from around the evaporator tubes (4).
24. To remove the blend-air door (1) from the inside of the HVAC housing (2), first carefully release the retaining tab of the blend door pivot lever (3) from the pivot shaft of the blend door, using a small pick-type tool.
25. Pull the blend door pivot lever out of the pivot shaft of the blend-air door.
26. Remove the air vane (1) from the upper half of the HVAC housing (2).
NOTE: If the rubber evaporator core seal is deformed or damaged, the seal must be replaced.
27. Remove the rubber evaporator core seal (3) from the HVAC housing.
NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.
28. Remove both blend-air doors (4) and the defrost/floor-air door (5) from the HVAC housing.
ASSEMBLY
NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, mode-air and blend-air doors.
1. Install the air vane (1) into the upper half of the HVAC housing (2).
NOTE: If the rubber evaporator core seal is deformed or damaged, the seal must be replaced.
2. Install the rubber evaporator core seal (3) into the HVAC housing.
NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.
3. Install both blend-air doors (4) and the defrost/floor air door (5) into the HVAC housing.
4. If removed, install the rubber flange (3) over the evaporator tubes (4).
NOTE:
- Make sure that the evaporator drain is clean and unrestricted and that the rubber seal and the rubber flange are properly positioned in the HVAC housings.
- If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
5. Carefully install the A/C evaporator (1) into the lower half of the HVAC housing (2).
6. If removed, install the rubber flange (3) over the heater core tubes (4).
NOTE:
- If the foam seal around the heater core is deformed or damaged, the seal must be replaced.
- Make sure that the foam seal and the rubber flange are properly positioned in the HVAC housing.
7. Carefully install the heater core (1) into the lower half of the HVAC housing (2).
8. Align the air door pivot shafts with the pivot holes in the HVAC housing and install the two halves of the housing together (4).
9. Install the eleven screws (6) and the two metal clips (5) that secure the two housing halves together. Tighten the screws to 2 N.m (17 in. lbs.).
NOTE: If any of the foam seals are deformed or damaged, the seal(s) must be replaced.
10. Install the foam seals (1, 2 and 3) onto the HVAC housing.
11. Position the floor distribution duct (2) onto the bottom of the HVAC housing (3).
12. Install the screws (1) that secure the floor distribution duct to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
NOTE: If the seal on the air door is deformed or damaged, the air door must be replaced.
13. Align the pivot shaft of the panel-air door (1) with the pivot hole in the top of the HVAC housing (2) and install the panel-air door into the housing.
14. Install the panel/defrost outlet (2) onto the top of the HVAC housing (3).
15. Install the six screws (1) that secure the panel/defrost outlet to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
NOTE: If the seal for the panel/defrost outlet is deformed or damaged, the seal must be replaced.
16. Install the foam seal (1) onto the panel/defrost outlet (2) located on the top of the HVAC housing (3).
17. Position the air inlet housing (2) onto the top of the HVAC housing (3).
NOTE: If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced.
18. Install the four screws (1) that secure the air inlet housing to the top of the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
19. Position the blower motor (4) into the HVAC housing (6).
20. Install the three screws (5) that secure the blower motor to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
NOTE: Make sure that all HVAC wire harness leads are correctly routed through the wiring retainers.
21. Install the HVAC wire harness (1) onto the HVAC housing.
22. Connect the HVAC wire harness to the blower motor resistor (2), recirculation door actuator (3) and the blower motor.
23. Align the blend door pivot lever (1) with the blend air door pivot shaft (2) located on the top of the HVAC housing (3).
NOTE: Make sure that the pivot lever retaining tab is fully engaged to the blend-air door pivot shaft.
24. Install the blend door pivot lever into the blend-air door pivot shaft.
25. Connect the lever and linkage rod (1) to the blend door pivot lever (4) located on the top of the HVAC housing (3).
26. Install the lever and linkage rod onto the blend door pivot shaft (2).
27. Install the evaporator temperature sensor (2) into the opening located at the top of the HVAC housing (4).
28. Position the blend door actuator (3) onto the HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the blend-air door linkage.
29. Install the three screws (5) that secure the blend door actuator to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
30. Connect the HVAC wire harness (1) to the evaporator temperature sensor and the blend door actuator.
31. Position the mode door actuators (3 and 4) onto the driver side end of the HVAC housing (1). If necessary, rotate the actuators slightly to align the splines on the actuator output shafts with those on the mode-air doors.
32. Install the three screws (5) that secure the mode door actuators to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
33. Connect the HVAC wire harness (2) to the mode door actuator.
34. Install the HVAC housing assembly.