HVAC Removal with Pictures

[Bill Stockard]

Thanks to Bill for reminding it was in Issue 79... although at least in the on-line version it starts on pg. 20.

I was mistaken. I referred to the wrong magazine. Many of the original photos are in Issue 55, page 42 and 43. It's available online... I just checked.

Bill

 

[kuss]

Thanks for the update, those pics in the mag are a help. Bill do you have any contact with Scott Broderson? It seems he was hosting his photos on TDR, I wonder what happened to them. I'm in a bind needing to get this done before a week-long trip for my kids' Spring Break...

 

[Bill Stockard]

Thanks for the update, those pics in the mag are a help. Bill do you have any contact with Scott Broderson? It seems he was hosting his photos on TDR, I wonder what happened to them. I'm in a bind needing to get this done before a week-long trip for my kids' Spring Break...

No I don't have a contact information on Scott. You might try sending him a Private Message or an e-mail. By "clicking" on his name on the original post, he appears to be a current member.



Bill

 

[kuss]

My 10-yr old just showed me how to cut /paste the "photo web address" into a new window and voila, there's the photo! slower than seeing them all in one place, but it works.

 

[Bill Stockard]

My 10-yr old just showed me how to cut /paste the "photo web address" into a new window and voila, there's the photo! slower than seeing them all in one place, but it works.

Why didn't I think of that... I guess because I'm not a 10 year old. :-laf



I cut/copy and past all the time, but copying and pasting those links didn't occur to me either. Glad to her you finally got the photos to help with your project.



Bill

 

[JHumphries]

For the last month, I have not been able to control air flow between the floor and defrost. Therefore, I thought it was time to replace the defrost door (TSB 24-004-03). I decided to take a few pictures of the removal process. I have also included brief instructions. This was the first HVAC unit I have removed, it took about 8 hours to remove, repair, and replace using hand tools.

1. Evacuate AC system.
2. Drain two or three gallons of antifreeze from the radiator.
3. Disconnect battery ground cables.
4. Disconnect heater hoses from heater core. Tape over the heater core tubes to prevent leaks during HVAC removal.
5. Loosen accumulator mounting bolts and disconnect evaporator lines using disconnect tool. Tape over tubes and line openings to prevent contamination and leaks during removal.
6. Remove nuts from the two HVAC studs.
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7. Remove center console, I choose to remove shift lever also. If you do not have a center console then a small trim panel will need to be removed.
8. Remove center IP bolts.
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9. Remove left and right a-pillar trim, side covers, and cowl trip panels.
10. On left side, remove the knee blocker trim panel and trim panel around the park brake release handle.
11. Disconnect park brake release rod.
12. Remove the three left IP attachment bolts.
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13. Remove the three right IP attachment bolts.
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14. Disconnect electrical and radio antenna wire connectors behind right cowl trim panel.
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15. Remove bolt attaching metal strap to HVAC housing (under glove box)
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16. Remove top IP cover. First pry up on the back of the panel to disconnect rear clips. Then pull panel back to unsnap front clips.
17. Remove 4 small screws and 2 bolts attaching the upper IP to body.
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18. Remove the bracket holding the diagnostics port and hood release lever.
19. Remove 4 nuts attaching steering column. Lower steering column until the steering wheel rests on the driver’s seat. Be sure to watch the brake switch as it could be damaged.
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20. Remove both column support bolts above steering column.
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Fixed and I'm not 10!

 

[JHumphries]

21. Pull IP back.
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22. Remove lower HVAC housing mounting bolt.
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23. Remove two nuts on upper HVAC mounting studs.
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24. Remove the HVAC unit.
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25. Disassembly HVAC unit and replace any broken components.
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Round 2...

 

[JHumphries]

During disassembly I found just what I was looking for, a broken defrost door.
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The door broke after the actuator stop broke on the lower HVAC housing.
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The new lower housing has a more durable stop.
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I also choose to replace the recirculation door even thought it was not yet broken, probably just a matter of time. The recirculation door is now serviced as an assembly. You get the housing, door, actuator adapter, and actuator.
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No motor actuator stops on the old recirculation housing.
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New recirculation housing has actuator stops.
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New parts list:
5127758AA – Lower HVAC housing - $43
5073964AA – Defrost door – $19
5019632AA – Coupling - $7
68004226AB – Recirculation housing w/ door and actuator- $20
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Lastly, here is a picture of the evaporator with the temp sensor in the factory location.
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I'm hoping to do this repair soon, so I thought I would make it easier on myself and fix the pictures...

 

[Sled Dog]

Great Job!

 

[kuss]

Nice job, JH! That will surely help countless people down the road!