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The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor, blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: “Body and Frame : Interior Moulding/Trim : Dashboard/Instrument Panel : Service and Repair” See: Body and Frame\Interior Moulding / Trim\Dashboard / Instrument Panel\Service and Repair 3. If the vehicle is not equipped with air conditioning, go to Step 6. If the vehicle is equipped with air conditioning, recover the refrigerant from the refrigerant system. Refer to: “Heating and Air Conditioning : Service and Repair” See: Service and Repair 4. Disconnect the liquid line refrigerant line fitting from the evaporator inlet tube. 5. Disconnect the accumulator inlet tube refrigerant line fitting from the evaporator outlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Drain the engine cooling system. Refer to: “Engine, Cooling and Exhaust : Cooling System : Service and Repair” See: Engine, Cooling and Exhaust\Cooling System\Service and Repair 7. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes. 8. Remove the four nuts from the heater-A/C housing mounting studs on the engine compartment side of the dash panel. 9. Remove the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. 10. Pull the heater-A/C housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes. 11. Remove the heater-A/C housing from the vehicle. DISASSEMBLY 1. Place the heater-A/C housing on a work bench, with the heater-A/C housing cover facing down. 2. Remove the two screws that secure the heater-A/C housing cover to the top of the blower motor housing cover. 3. If the vehicle is so equipped, unplug the two vacuum harness connectors from the recirculation air door actuator. 4. Unplug the vacuum harness connector from the panel-defrost door actuator. 5. Remove the four screws that secure the floor duct to the bottom of the heater-A/C housing and remove the duct from the housing.

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The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor, blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery 4. Remove the front expansion valve from the evaporator tube mounting flange. Install plugs in, or tape over all of the opened refrigerant line fittings. Refer to: Heating and Air Conditioning, Expansion valve, Service and Repair, Expansion Valve Removal and Installation, See: Expansion Valve/Service and Repair 5. Drain the engine cooling system. 6. Disconnect the heater hoses from the heater core tubes.

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Housing Assembly HVAC: Service and Repair The heater-A/C housing assembly must be removed from the vehicle and the two halves of the housing separated for service access of the heater core, evaporator coil, blend-air door(s), and each of the various mode control doors. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Procedures/Instrument Panel Assembly Replacement 3. Recover the refrigerant from the refrigerant system. See: Refrigerant/Service and Repair 4. Disconnect the liquid line refrigerant line from the evaporator inlet tube See: Hose/Line HVAC/Service and Repair. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Disconnect the suction line refrigerant line from the evaporator outlet tube See: Hose/Line HVAC/Service and Repair. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Disconnect the heater hoses from the heater core tubes. Clamp off the heater hoses to prevent loss of coolant. Install plugs in, or tape over the opened heater core tubes. 7. If the vehicle is equipped with the manual temperature control system, unplug the heater-A/C system vacuum supply line connector from the tee fitting near the heater core tubes. 8. Remove the coolant reserve/overflow bottle from the passenger side inner fender shield. 9. Remove the Powertrain Control Module (PCM) from the passenger side dash panel in the engine compartment and set it aside. Do not unplug the PCM wire harness connectors.

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NOTE: The recirculation control motor, the power transistor, the blower motor high relay and the blower motor can be replaced without removing the blower unit. Before reassembly, make sure that the recirculation control doors and linkage move smoothly without binding. After reassembly, make sure the recirculation control motor runs smoothly. Make sure that there is no air leakage.

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Overhaul NOTE: • Before reassembly, make sure that the recirculation control doors and linkage move smoothly without binding. • When
reattaching the recirculation control motor, make sure its positioning will not allow the recirculation control doors to be pulled too far. Attach the recirculation control motor and all links, then connect power and ground, and watch the movement of the recirculation control doors. RECIRCULATION CONTROL MOTOR Test, page 21-27 Replacement, page 21-27