Overhaul
DISASSEMBLEHeater-A/C housing must be removed from vehicle before performing this operation.
Fig. 4 Heater - A/C Unit Housing:
1. Place Heater-A/C unit assembly on workbench.
Fig. 5 Recirculation Housing Removal:
2. Remove upper recirculation air inlet housing.
3. Front air inlet door and lever is serviced with recirculation housing.
Fig. 6 Blower Motor Resister:
4. Remove blower motor wiring at resistor.
Fig. 7 Blower Motor:
5. Remove blower motor.
Fig. 8 Evaporator Fin Sensor:
6. Using a flat blade pry tool, Pull up on tab at evaporator fin sensor cover. Turn evaporator probe cover clockwise 90 °.
7. Remove evaporator fin sensor cover. Pull evaporator sensor from evaporator.
Fig. 9 Housing Clips:
8. Remove clips retaining evaporator housing to heater/distribution housing.
Fig. 10 Separate Housings:
9. Separate evaporator housing from heater/distribution housing.
Fig. 11 Evaporator Tube Inlet Seal:
10. Remove seal around evaporator tube inlet.
Fig. 12 Evaporator Housing Upper Cover:
11. Remove evaporator housing upper cover.
Fig. 13 Remove Evaporator From Housing:
12. Lift evaporator out of lower housing.
13. Remove styrofoam seal around evaporator.
Fig. 14 Retaining Clips Removal:
14. Remove lower heat/distribution housing clips. Remove housing.
Fig. 15 Heater Core Cover:
15. Remove heater core cover.
Fig. 16 Heater Core Cover Removal:
16. Slide heater core out of heater housing.
Fig. 17 Temperature Door Removal:
17. Press tab in at base of temperature door and release door from lever. Then remove the door.
Fig. 18 Mode Door Removal:
18. Press tab in at base of mode door and release door from lever.
Fig. 19 Cam Screw Removal:
19. Remove Heat/Defrost door cam screw.
Fig. 20 Cam and Lever Removal:
20. Lift the cam and mode door lever off of the housing.
Fig. 21 Pivot Screw Removal:
21. Remove the Heat/Defrost link pivot screw.
22. Lift the Heat(Defrost link and the door as an assembly. Then separate the link from the door.
ASSEMBLE
1. Install the Heat/Defrost link and the door as an assembly. The connect the link to the door.
2. Install the Heat/Defrost link pivot screw.
3. Install the cam and mode door lever to the housing
4. Install the Heat/Defrost door cam screw.
5. Install the mode door to the lever.
6. Install the temperature door to the lever.
7. Install the heater core into the heater housing.
8. Install the heater core cover.
Fig. 22 Retaining Clips Removal:
9. Install the lower heat/distribution housing clips.
10. Install the styrofoam seal around the evaporator.
11. Install the evaporator into the lower housing.
Fig. 24 Evaporator Housing Upper Cover:
12. Install the evaporator housing upper cover.
Fig. 23 Evaporator Tube Inlet Seal:
13. Install the seal around the evaporator tube inlet.
14. Install the clips that retain the evaporator housing to the heater/distribution housing.
Fig. 25 Evaporator Fin Sensor:
15. Install the evaporator sensor into the evaporator.
16. Install the evaporator fin sensor cover.
17. Install the blower motor wiring at the resistor.
Fig. 26 Blower Motor:
18. Install the blower motor.
19. Install the upper recirculation air inlet housing.
Fig. 27 Heater A/C Unit Housing:
20. Remove assembled heater-A/C housing and place in vehicle.
21. Install the heater-A/C housing in vehicle.