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.
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.
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.
13. Remove the three right IP attachment bolts.
14. Disconnect electrical and radio antenna wire connectors behind right cowl trim panel.
15. Remove bolt attaching metal strap to HVAC housing (under glove box)
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.
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.
20. Remove both column support bolts above steering column.
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