Heater-A/C Housing Disassembly and Assembly

Fig 45 Heater & A/C Unit Housing:

UNIT HOUSING RECONDITION

NOTE: Heater-A/C housing must be removed from vehicle before performing this operation.

DISASSEMBLE
1. Place Heater-A/C unit assembly on workbench.

Fig 46 Recirculation Housing Removal:

2. Remove upper recirculation air inlet housing.
3. Front air inlet door and lever is serviced with recirculation housing.

Fig 47 Blower Motor Resistor:

4. Remove blower motor wiring at resistor.

Fig 48 Blower Motor:

5. Remove blower motor.

Fig 49 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 50 Housing Clips:

8. Remove clips retaining evaporator housing to heater/distribution housing.

Fig 51 Separate Housings:

9. Separate evaporator housing from heater/distribution housing.

Fig 52 Evaporator Tube Inlet Seal:

10. Remove seal around evaporator tube inlet.

Fig 53 Evaporator Housing Upper Cover:

11. Remove evaporator housing upper cover.

Fig 54 Remove Evaporator From Housing:

12. Lift evaporator out of lower housing.
13. Remove styrofoam seal around evaporation

Fig 55 Retaining Clips Removal:

14. Remove lower heat/distribution housing clips. Remove housing.

Fig 56 Heater Core Cover:

15. Remove heater core cover.

Fig 57 Heater Core Cover Removal:

16. Slide heater core out of heater housing.

Fig 58 Temperature Door Removal:

17. Press tab in at base of temperature door and release door from lever. Then remove the door.

Fig 59 Mode Door Removal:

18. Press tab in at base of mode door and release door from lever.

Fig 60 Cam Screw Removal:

19. Remove Heat/Defrost door cam screw.

Fig 61 Cam And Lever Removal:

20. Lift the cam and mode door lever off of the housing.

Fig 62 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
To reassemble, reverse the above procedures.