Overhaul

DISASSEMBLY
1. Remove the HVAC housing from the vehicle. Removal and Replacement
2. Place the HVAC housing with the tubing side down on a work bench, making allowance for leakage of fluids.

Fig.12 Split Foam Seal At Panel Outlet:

3. Using a sharp knife, split the foam seal surrounding the panel outlet opening, at the dividing line of the upper and lower cases.
4. Place the HVAC housing in the upright position on the work bench.

Fig.13 Mode Door Actuators - Manual System:

Fig.14 Mode Door Actuator - AZC System:

5. Remove the mode door actuator on the left side of the housing, which controls the mode door in the top of the case.

Fig.15 Remove Screw With Plastic Washer:

6. Remove the screw with plastic washer holding the lever assembly to the upper case section, and move aside.

Fig.16 HVAC Housing Clips:

7. Remove the 5 clips that secure the two housing halves to each other. There are 2 on either side at the center, and 1 located at the forward end of the mode door side of the case.

Fig.17 Wire Harness Electrical Connector(s):

8. Release the wire harness electrical connector(s) from the mounts on the lower case at the blower motor end of the unit.
9. Remove the 10 screws that secure the two housing halves to each other.

Fig.18 HVAC Housing-Case Seperated:

10. Separate the top half of the HVAC housing from the bottom half.

Fig.19 Blend Door Sub-Assembly (AZC):

NOTE: The blend door sub-assembly is attached to the housing with 2 screws, and may be removed for service.

ASSEMBLY
1. Place the top half of the HVAC housing on the bottom half. Be certain that each of the door pivot pins align with the pivot holes in the HVAC housing.
2. Install the 10 screws that secure the two housing halves to each other. Tighten the HVAC housing screws to 2.2 Nm (20 in. lbs.).
3. Attach the wire harness electrical connector(s) to the mounts on the lower case at the blower motor end of the unit.
4. Install the 5 clips that secure the two housing halves to each other. Check doors for binding after replacement, and after assembly of housing.
5. Install the screw with plastic washer holding the lever assembly to the upper case section.
6. Install the mode door actuator on the left side of the housing.