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HVAC Housing






HOUSING-HVAC

Special Tools:






NOTE: A/C equipped model shown in illustrations. Heater only models similar.





1. Remove the HVAC housing assembly and place it on a workbench HVAC Housing - Removal.
2. Remove the air inlet housing from the HVAC housing HVAC Housing - Removal.
3. When equipped with MTC, use a small screwdriver or similar tool and carefully remove the retaining clip (1) from the left side of the HVAC housing (4) and disconnect the mode control cable (2) from the mode door cam (3).





4. When equipped with ATC, disconnect the wire harness connector (5) and remove the two screws (4 and 6) and the mode door actuator (2) from the bracket (3) on the left side of the HVAC housing (1).





5. When equipped with ATC, remove the three screws (1, 3 and 5), actuator bracket (2) and actuator gear (6) from the left side of the HVAC housing (4).





6. Disconnect the wire harness connector (2) from the blower motor (4).
7. Remove the three screws (1 and 3) that secure the blower motor to the HVAC housing (5) and remove the blower motor.





8. When equipped with MTC, use a small screwdriver or similar tool and carefully remove the retaining clip (1) from the right side of the HVAC housing (3) and disconnect the temperature control cable (4) from the blend door cam (3).






CAUTION: Use care when removing the blend door actuator to prevent damage to the blend door linkage. If required, disconnect the blend door linkage from the blend doors and then separate the linkage from the blend door actuator.

9. When equipped with ATC, disconnect the wire harness connector (2) and remove the two screws (3 and 4) and the blend door actuator (1) from the right side of the HVAC housing (5).





10. When equipped with ATC, remove the instrument panel air outlet temperature sensor (3) from the right side of the HVAC housing (4) using Trim Stick (C-4755) (1) or equivalent, and disconnect the HVAC wire harness (2) from the sensor.





11. When equipped with ATC, remove the floor air outlet temperature sensor (3) from the right side of the HVAC housing (2) using Trim Stick (C-4755) (4) or equivalent, and disconnect the HVAC wire harness (1) from the sensor.





12. When equipped with ATC, disconnect the wire harness connectors (3) and remove the two screws (2 and 4) and the blower motor power module (1) from the right side of the HVAC housing (5).





13. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (5) and the MTC A/C heater module (2), when equipped.
14. Remove the screw (6) that secures the HVAC wire harness bracket (4) to the HVAC housing.
15. Disengage the HVAC wire harness from the plastic retaining brackets (3 and 8) and remove the HVAC wire harness.





16. When equipped with MTC, remove the three screws (1 and 3) that secure the A/C control module (2) to the right side of the HVAC housing (4) and remove the module.





17. Remove the two screws (1 and 3) that secure the particulate air filter cover (2) to the right side of the HVAC housing (4) and remove the cover.





18. Remove the particulate air filter (1) from the right side of the HVAC housing (3). Make note of the air flow direction (2).





19. Remove the six screws (1) that secure the condensate drain (2) to the bottom of the HVAC housing (3) and remove the drain.





20. Using needle nose pliers, remove the evaporator temperature sensor (1) and retaining clip from the A/C evaporator (2).






NOTE: If the foam seal at the front of the HVAC housing is deformed or damaged, it must be replaced.

21. Remove the foam seal (1) from the flange at the front of the HVAC housing (2).





22. Remove the three screws (1 and 2) that secure the heater core cover (3) to the left side of the HVAC housing.
23. Remove the heater core cover from the HVAC housing.






WARNING: Use care when removing the heater core. Do not apply excessive force to the heater core tubes. Failure to follow these instructions can result in a possible engine coolant leak and serious or fatal injury.

NOTE: If the foam seal around the heater core is deformed or damaged, it must be replaced.

24. Carefully pull the heater core (1) out of the left side of the HVAC housing (2).





25. Remove the ten screws (2) that secure the two halves of the HVAC housing together (1).
26. Carefully separate the two halves of the HVAC housing.






NOTE: If the foam insulator for the evaporator is deformed or damaged, it must be replaced.

NOTE: If the foam seal for the evaporator tubes is deformed or damaged, it must be replaced.

27. Remove the A/C evaporator (1) and the A/C expansion valve (2) as an assembly from the left side of the HVAC housing (2).
28. If required, remove the A/C expansion valve from the A/C evaporator A/C Evaporator - Removal.






NOTE: Manual Temperature Control (MTC) shown. Automatic Temperature Control (ATC) similar.

NOTE: For ease of reassembly, make note of the installed position of the two blend air doors, prior to removal.

NOTE: If a rubber seal on a blend air door is deformed or damaged, the door must be replaced.

29. Perform the following if removal of the blend air doors from the right side of the HVAC housing (6) is required.
- Using a small flat bladed tool, carefully disengage the retaining tabs (4 and 7) that secure the blend door gear (1) and the blend door lever (3) to the blend air doors (5 and 8).
- Remove the blend door gear, rod (2), lever and blend air doors.





NOTE: For ease of reassembly, make note of the installed position of the floor mode air door, prior to removal.

NOTE: If a rubber seal on a mode air door is deformed or damaged, the door must be replaced.

30. Perform the following if removal of the mode air doors from the left side of the HVAC housing (9) is required.
- Rotate the mode door cam (8) so that the two arrows (2 and 11) align with the tabs on the two mode door gears (1 and 3).
- Remove the screw (10) that secures the mode door cam to the left side of the HVAC housing.
- Using a small flat bladed tool and carefully disengage the retaining tab (6) that secures the mode door lever (4) to the floor mode air door (5).
- Remove the mode door cam, mode door rod (7), mode door lever and the floor mode air door.





NOTE: For ease of reassembly, make note of the installed position of the mode air doors, prior to removal.

NOTE: If a rubber seal on a mode air door is deformed or damaged, the door must be replaced.

31. Using a small flat bladed tool, carefully disengage the retaining tabs (5 and 7) that secure the mode door gears (1 and 3) to the mode air doors (2 and 4) and remove the gears and doors from the left side of the HVAC housing (6).

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