Heater-A/C Housing Disassembly and Assembly

The Heater A/C housing must be removed from the vehicle to recondition.

DISASSEMBLY
Remove the Heater Core assembly from the housing. Refer to: "Heater Core : Service and Repair" Service and Repair

Evaporator Sensor Wiring:

1. Remove the wiring at the evaporator sensing probe.

Weather-Strip Seals:

2. Remove heater outlet weather-strip seals at duct openings.

Cowl Air Intake:

3. Remove weather-strip seal at cowl air intake.

A/C Heater Housing Retaining Screws:

A/C Heater Housing Retaining Clips:

4. Remove screws and clips retaining upper housing to lower.

A/C Heater Housing Halves:

5. Separate housing halves.

Evaporator Sensing Probe:

Evaporative Sensor:

6. Remove evaporator sensing probe from the center of the evaporator and remove probe from housing.

Evaporator Removal:

7. Remove evaporator from housing.
8. Turn lower housing over.

Vacuum Actuator Cover:

9. Remove the vacuum actuator cover.

Door Identification:

10. Mark the vent actuator bracket and the vent door shaft for assembly identification. The vent door and the Heat/Defrost door look similar but are different.

Vent Door Actuator Level:

Heat/Defrost Door Actuator Lever:

11. Remove the screws retaining the actuator levers to the doors.

Vent Door Actuator:

12. Remove the vent door actuator.

Heat/Defrost Door Actuator:

13. Remove the heat/defrost door actuator.

Vent Door:

14. Remove the vent door from the housing.

Heat/Defrost Door:

15. Remove the heat/defrost door from the housing.

SUBASSEMBLY RECONDITION

Thermostatic Expansion Valve:

The thermostatic expansion valve (TXV) is located at the evaporator inlet.

REMOVAL

Insulation Removal:

1. Cut away and remove insulation around TXV capillary tube.

Capillary Tube:

2. Remove capillary tube from clip at the evaporator outlet.

Evaporator Inlet Line:

3. Remove evaporator inlet line from TXV.

TXV Outlet:

4. Remove flange nut at TXV outlet.

ASSEMBLY
To assemble the Heater A/C housing reverse the above procedures. The heater core tubes are offset and must be installed in the proper manner.

The Heat/Defrost door and the Vent door are not identical. These doors must be installed properly.