Howdy Folks Good day to you! Welcome back! Glad you guys are here. This is a bonus shoot type of video. It is the end of day. uh Dave and my wife unit have left and gone home for the evening.

I'm going to stick around for a little bit of time because I have a goal to get this uh, this explosion of a project kind of completed or at least make some progress towards it. Uh, this all started a couple weeks ago when I decided it was going to be a good idea to reupholster my headliner and after I had I had learned that I had to pull the seats out in order to get the headliner out of the vehicle. Uh, since I had to pull the seats out I was like hey, I have a brand new box of carpet which is in the back of the truck I have a brand new box of carpet. Let's pull the carpet out and change out that carpet while the seats are out.

Well after I pulled the carpet out, I realized that the insulation under the carpet was absolutely nasty and destroyed and gross and it stunk really bad. Uh, additionally, some of the insulation that was foam backed that had a rubber uh, I had found that the rubber was disintegrating and turning into powder. Uh, therefore I wasn't comfortable with putting a new carpet on top of destroy installation and I figured since I was going to pull the insulation out, I was going to have to pull the dash out and since I had to pull the dash out, I was going to pull the Hbac box out because the evaporator has had some kind of a clog or restriction in it for well over a year and it's been causing me to have poor AC uh cooling system performance. So this, uh, this project has sort of snowballed into a restoration project rather than a repair project.

I've been putting in uh, some new sound and heat insulating uh insulation and um, I'm waiting for a little bit, uh, a little bit more of this material to show up that's actually thicker that I can use for the firewall section. Uh, once that is, uh in place I can then work on getting this Hbac box back uh installed on the firewall. However, at 230,000 MI I don't feel I should just be putting this box back in as it is. So I'm going to rebuild this box as best I can while it's out.

Uh, what that means is I need to blow all the dirt out of it. I'm going to replace all these actuator Motors because these are very hard to get to, those are going to be changed. We're going to check on the condition of these uh, these foam seals and those are not really looking that good. So I may replace this foam while I'm here.

Uh, I have over here in some boxes a replacement heater core. that's this unit right here, little miniature radiator and I have the AC evaporator right down here. So what we're going to do today on this little bonus video is: I'm going to get this unit up on the bench and we're going to disassemble this Hbac box and get the uh, the cooling system cores out of it, reassemble it, put it back together, and then uh, it'll be prepped and ready to be reinstalled. So stay tuned because this is going to be a very good video uping y Hood Look who that guy is.

Well, first off, I need to deal with the unpleasant portion of this first and that's going to be deifying all this buildup and debris and dust and grass and leaves and whatever else is in there. So we're just going to blow that off with the air gun. It's going to make a little bit of noise, we're going to get it preliminarily cleaned, and then we can start this assembly. Loud noises, Pine needle, goodbye.

All righty. So I Have not been into one of these Agback boxes for a very, very long time. This is kind of a rare procedure and I don't think I've ever done one on uh, on a Chevrolet truck. As odd as that sounds, it's just not something that, um, that's really come across me.

Uh, what I'm getting at is I'm not exactly sure the order of operations here, so we're just going to start taking things apart and see how this works out. Now we have identified this right. Here is the heater core. those are the hoses for it.

The evaporator is over here on this other side. so this section here looks like it's some type of, uh, like a cover. so we're going to pull this off. I think it's got 5 1/ 12 mm bolts going to pull these guys out and see if that's our heater core or if that's how this core comes out? I'm fairly certain that for the Uh evaporator, I'm going to have to split the case into two.

Yeah, yeah, but for the here cor it just looks like it's got a little slot here that you just slide that thing on out. so let's wiggle this guy out of its home. See what we're looking like here? Not too bad, pretty decent. but I did order a new one because this one's been here for 230,000 Mi and I don't want it to leak I Would hate to have it leak and ruin my brand new carpet but I have not installed yet.

so Looking Down in the Hole I'm not seeing anything really much to look at in there. There's no debris so let's uh, let's move on. take some more panels off again. I'm going to replace probably everything on this I do have new actuators so I think I want to start from this side and go that way.

Let's remove this area right here. This is the air Inlet vent. We have one actuator on a flapper valve right here and we can select either recirculate mode and draw in air from inside of the cabin. or we can draw in fresh air from outside of the cabin.

that's uh, usually a little bit of a different temperature. So I like to keep it on um on Reser mode. It helps to keep things cool. So let's pull this actuator off and then take this.

uh, this door apart. like I said I'd like to replace some of these foam foam sealers and everything on here because they don't appear to be in the best of condition. Okay, we saw the door start to swing. see that and looks like we've got two more 5 and 1 halfs right here and right here.

and then this whole door section should hinge and come off of there. Pull all this stuff apart. Restoration action: Yeah, that foam's not in the greatest condition here. and I guess it works.

I'd like to replace the doors, but I don't think that they're available regardless. I can at least clean this out really nice and potentially refoam this. I think I have some foam that's the right dimensions. I'll see what I've got in the in my inventory.

Yeah, look at here. all kinds of dirt and dust and debris. This is our cage for our our blower fan and we've got some wires going on here so that's not. It's not how we need to access the uh evaporator.

so let's give this thing a flip. We're going to roll it over and see what other uh, bolts and whatnot we can remove. Flip it over this rubber thing right here. That's the drain.

uh for the evaporator little drain pipe thing. Okay, got a bunch more bolts around the perimeter. Over here. On this side, we are looking at the blower motor and the blower motor resistor.

I'm going to disconnect these components. Rat meow. Get this stuff out of here. Unclip the clip.

It's all getting reused. I'm not. uh, replacing the blower or the resistor. These are fairly easy to access, but I am going to pull all this stuff off for cleaning and inspection.

A little bit of corrosion in there. It's not okay. it's not horrible, but it's not the greatest. and I think this motor just rotate it there.

We go, pick up the tab, rotate it, and it unlocks. That's our floor motor, fan cage. and yeah, that thing's loaded full of dust and dirt and debris. It made like a vibration while running in.

Clearly it's out of balance with all that dirt build up. so we're going to clean that off later and going around the perimeter. I'm not too much cause for concern. Let's pull off this piece of uh of the ducting right here.

That's got to go. Looks like we have just one. Fastener wiggle that out. Nothing inside.

We'll set this thing off to the corner. H Okay, there's another duct over here. two bolts. Let's pull this guy off.

more foam. Yay! what's this thing do? It's clearly another door, but it doesn't want to move. That's fine here. There's some duct work.

Pull this out of here and that's attached with a couple sensors. Okay, we have two vent temperature sensors in here. Let me unplug these units. That's one side and here's the other one.

way over y under. Okay, set that piece of plastic aside I see more doors and that still does not move. Oh, how do we get this thing to come apart? There's plastic, looks like plastic rivet type of things in here. I may have to drill this out.

r r Okay, so not certain uh exactly how this goes, but it appears that we have some some Fasteners that, uh, support their or attach the two halves of this unit. but then it also appears that these are plastic welded in. so I may have to Source some Fasteners cuz there are holes for bolts here, but they just were never installed. Uh, probably a cost-saving measure.

So I'm going to have to drill those holes out these uh, these rivets here and then use those bolt holes with some screws to reassemble this. So uh, I think I'm going to go ahead and finish disassembling the actuators. Let's get these guys disconnected. There's that one there.

Go ahead and detach This. cuz this one is secured to both halves. I Think and if it's not, then I'll deal with that in a minute. Why are not fitting Oh wrong size, wrong socket.

It's the 5 1/2 mm there. Pull you out and then this actuator can come free. How's this work like that? Okay, we'll leave you there for now and we'll leave the big cam. We'll let that kind of just dangle for right now.

Okay, so let's go around and lose all of our small bolts ones that are in there. and then we'll get the drill. Pull all this stuff apart. There is a modification where you can cut like this box out and then just kind of glue it back together in order to avoid separating these two halves.

I'm not going to cut my box open so we're not. Uh, we're not doing that. We're just going to unbolt it and then lose the drill or use the drill and then re- rivet it or something like that. Okay, I think that's all the all the bolts that are in it.

Pull that one out one more over here. Come here, lost bolt to the pile with you. Let's start with these holes here and I'm going to try to drill the top of this out without going too deep and then we'll get a uh like a screwdriver under there and then break off whatever plastic is left holding on to uh two halves. here.

There we go. Let's get under that with a pocket screwdriver and try to pry these two pieces apart. Yeah, did you hear that crack? That's the plastic. Whatever was left breaking away, so this is effective.

We just have to kind of keep at it. continue to drill these guys out, break them loose, and separate these two halves. Yep, see that now. we're getting some motion out of it.

Just keep on going down the line here. I'm not going to lie. I'm a little nervous about this cuz if I drill too much or do this wrong I can potentially ruin this whole box cuz if I can't get it to go back together, uh, I'm going to have a problem if not drilled enough. I wonder if a larger drill bit would be more beneficial here.

larger diameter. Give it a pull. There we go. That one crack loose.

Okay, so I think it's a little bit of light drilling action. There we go. Yeah, a little bit of light Drilling and some frying should, uh, should open this up. Yep, that one popped loose.

this one. not so much. Okay, now we're loose. so that's this whole side.

Let's take this whole box, flip it around and we can drill the uh, the back side here. Drill bit gravity. There we go. There's no hole there, one over here and I think there's like one or two over here getting closer.

Oh yeah yeah, it's all apart. I think maybe one or two on this other side. Yep, they just popped and snapped the uh case is now separated. Here we go.

That's what we're looking for. This thing apart. yeah, that's not the greatest in there. Pretty dirty look at all that build up.

Okay, this things needs a uh, a good and garden hose job and maybe I can put some new foam on these I don't know. uh. anyway, this that's our effective unit that is the AC evaporator. Pull off the little Shield here.

set this guy down out of the way for now and we, uh, we need to pluck this unit out I want to check it for clogs here and if I don't have any that go through I'm going to have to assume it's clogged internally, but I know that this AC system had a pressure problem of some sort. Wiggle this guy out and see if we can't see light through this unit. Yeah, not really. Oh yeah, there's I mean I see some light coming through, but it's not the greatest.

Let me try try the flashlight here. Some flashlight on the back side. Yeah, it's I See a lot of obstruction in there, a lot of dirt, build up, things of that nature. Very very inefficient unit, so it's partially restricted here for the air flow.

and I don't know if we have a restriction. uh in uh in the actual internals. It's possible I've tried to flush this out before, but uh, to no avail. Uh, either way, this is, uh, what we are looking for.

So what I need to do next is set that aside and going. take this down, blow everything out, clean it up, blow gun. Okay, so we did a bit of housekeeping on this. We've got it all wiped down, cleaned out, took all the uh, the panels off of it, got as much of the dirt removed as possible I inspected all, of, uh, all the foam seals inside and I've elected to not touch these.

Uh yes, I could use some insulation that I have and take this all off and cut new stuff. but I think that that what's going on here is better than what I could do. Uh, there is no uh, there's no indicator that any of these Foams are coming apart. so I'm just going to leave those alone.

So next on our list is, well, I guess it's time to get the uh, the evaporator back in position now. This one has some kind of a holder with this little, uh, little bracket thing that goes on there. So I'm going to have to reuse this unit, peel that off and clean that thing off too. and then the old unit can, uh, just get set aside.

Let's go ahead and match this up though. make sure that this is the correct component. I Hate to uh, go through all this and then have to, uh, find out it's the wrong one. It appears to be the correct size, shape, and dimensions.

Big Port Small Port Big Port Small Port So that, uh, confirms this is the correct evaporator. Now we just need to, uh, get it down inside of its home here after I spray all this nasty stuff off of uh, this little bracket deal right here. All righty. I Have the uh, the seal set up on the new evaporator, and now we just need to walk this thing down into its case, rock it in, and set that guy down into position.

Just like so, so that's the new evaporator. It's in half of the case and and this is our seal. I Think it went on like that? Yeah, we'll put that on in a minute. Do that later.

More broken plastic stuff. Okay, put the seal aside, let's grab the other half, set that one on, hook up that piece of linkage, and then get this thing bolted back down. Second half of the case. Coming in, evaporator is in position.

We have to mine this piece of linkage and feed it through this little hole here. But other than that, pretty straightforward. We just set her right on down in position, lining up that uh, piece of linkage over there, and it seems to be lining up and going back right where it's supposed to be. So all we need to do is, uh, run some screws into those holes there.

that thing's back together. After that, we'll change out the actuators, run the wiring harness, and then get all the other little miscellaneous pieces put back on. Okay Fasteners Coming in, got a box of generic stuff in the corner just used uh, used what? I had wrong size switch that back out to the quarter inch torque achieved I'm just going to run around the perimeter and everywhere where there was that plastic little weld we run in a screw. So far so good.

I like it. It's working out all right. We're coming up on heater core time. so there's our old unit and the new heater core.

again. these were GM part numbers original equipment. Let's start transferring some seals over. Let's get this piece of foam come out home.

swap that over onto our new one, slide that on right there. Now we see all this foam around this heater core. I have to replace that with uh, this piece of foam that they gave us so looks like I just need to just wrap it around the perimeter. I Guess I'll start right here at the top and just move it around.

Sure! So yep, that's adhesive back. put the piece right in there and I'll walk it all the way around the perimeter, stick it on right there. a little bit more around the other side. I See a lot going on here again.

Another job bigger than I Thought it was going to be foam foam foam all the way around and we're going to close it off right there with a I guess a little extra I'll just leave it there and smash it down. Okay, so we have our foam all around the perimeter. I'm not sure what to do about this little piece of foam here in the middle. I don't think we need it I'm not going to use it.

Set that aside now. take our core and slide it down into the case. That's a tight squeeze with that piece of foam in there. Here we go slide it down.

There are some tracks that this is riding in guiding it into position and I think we're good right there Now we can put the lid back on and bolt that section down. All right that things in position. Let's get the Fasteners fastened. There's three of them I Believe Good Okay, lid is on, Heater core installation is now complete.

All right. let's move this unit on over and we can set up the uh intake scoop it. Uh, it's got two little tabs here. that tab into those tabs and then it sort of hinges down and then screws in.

So let's take that guy get you set up right there. two screws. I'm going through what? I know because I forgot the the way that the wire harness goes. So I'm going to get all the pieces on, change out the actuators with the new ones and then see how those wires are supposed to run.

We can figure it out. Okay, that is our recirculation door and I believe that it has an actuator somewhere. Oh yeah, yeah, right over here. That's that's where the actuator screws in that side.

Okay, rotate this thing some so we can get a good line of sight on it. Got one actuator here. This is one of the new units. We're going to slide that over the little hinge piece right there and then snap that into two position so that door is now stationary.

it cannot move. Got two more Fasteners one here and one here. Uh, where's my my tool W almost lost it. There we go.

That guy's on was that three? Fasteners or two looks like just two. Okay, that thing set up. let's flip the Box over and let's see. we can go ahead and put the foam seal on this side that goes right over that.

just like So now let's go ahead and get the Uh blower motor reinstalled, flips it down like so, and then we rotate to lock it in. That goes there. Our resistor comes in next and again two more Fasteners starting to run low on Fasteners Good. All right resistor is installed.

we can plug the motor back in. That's good. Let's get the rest of the actuators set up. We've got one right here.

that's one of the older ones, so we're going to pull that actuator off. Wiggle wiggle Yeah! New actuator coming in GM part it says made in Korea line that guy up two more bolts I'm assuming that's South Korea I Don't think North Korea exports very, very much. Okay, two actuators changed out. Good time to flip it again.

We have another actuator here on the far side. This also comes with some linkage. The linkage stays actuator uh mounts onto it. So let's see how we do this here.

Back words: We do it backwards. There we go. That one's in position. Two more screws again which I'm running low on screws.

Set that down. Find those other screws. Get that one in that one numeral Uno and numeral do. Entering the home stretch.

Now we're getting somewhere. Guys, definitely getting somewhere. Stay all right. Next up, we've got one piece of vent that Gu is going to settle down right over top of this vent area.

I Think this is the deflector for the side vents. Maybe could be for the floor? I Don't know. Keep flipping this thing over so often I Become disoriented, but it has one screw that retains it and there's another vent piece that goes on over here. Vent click Next piece coming in I Believe that's going to slide over this component and then it's going to uh, screw in right here.

So this right here is a point of of potential. Improvement So what I'm going to do is since that's a little loose fitting. I'm going to put some tape on it, seal it up nice. Like click.

Yeah, see, that's just kind of floppy right there. I'm going to put tape around that. We have some aluminized insulating tape for Hbac systems. it's not for Automotive Hbac Systems but it will work cuz all it has to do is create some kind of a an air seal so we don't get any leakage.

Let's see here. get up under there like that, pull it kind of tight, wrap it around I Don't know if I'm going to do one course of this or two courses probably Overkill whatever I do. but this whole project is massive. Overkill Yeah, I think I'll do two courses.

so let's cut this right about here and then do one more wrap around here. we go pull that tape back and reaching down. Pull It On Through There's a sensor right down there I've got to watch out for that. but I think we're good.

Finish that off right here. Like so okay. that's nice and sealed up. Good to go in the same location.

We've got one more little vent device I Think it points this way. Yeah, cuz it can't go on that way. All right. Two screws on this unit.

click, plastic, click thread. It's getting late. a little tired I said earlier I was going to spend like an hour on this tonight. I'm coming up on hour number two I think Anyway, let's flip it over.

We've got one more actuator to go and then I'd like to uh, reroute the wires and whatnot and go from there. That's our last actuator and as a way to not get lost I left that last one attached to one of the Uh or to the harness. So now all I have to do is get this actuator set up properly and then make sure that this harness goes where it's supposed to. which.

I've got a couple guides here. there's this piece this actuator is going to plug in right there. Okay, so we're going to go this way with it. Figuring this out, bear with me here.

I'm actually going to mock this up some and then and uh, once it's mocked up properly and I know where everything goes. I'm going to ret tape all these wires right here because they're they're kind of ugly and I don't like them. I would like to have nice clean wires all right. I think we're good I have got it figured out.

they're all draped over properly and they appear to be form fitting correctly. So I'm going to go ahead and disconnect this old actuator, set it aside, get get the new one in position, make sure all that's clocked properly. There we go and I'm going to go ahead and grab some tape real fast, and I'm going to begin to tape all these up with some uh, some better looking tape that's not the uh, rubberized electric tape. I don't like the rubber tape.

it gets all sticky and gross I prefer to use the uh, the foam tape. so I'm going or uh, the cloth tape rather. so I'm going to tape this up real fast and then we can Bolt the rest of the stuff down and get it all secured and we'll be all set. Okay, that's all in good condition.

Let's just squeeze the tape down. Some need to finish it off a little bit on this one section right here actually. I'm going to start from the connector side and work my way down and do that a little bit more tape just to make it nice and pretty and uniform. One more wrap and then through the middle of the Y and then around like.

so this is a thick part of the wire so there should be enough surface area to make that final piece. Bond Very well, that's good and we squeeze it. Bond it just like. So now this guy is going to go here as it plugs into our actuator and then the actuator sits right here in its home.

Let's get that thing set up. I Need to tape up that right there as well. That one's got me. Let's peel that guy out and this harness is supposed to sit here.

So I'm going to tape that on right there. There's no reason to not go this deep into this project considering how far we've come I Know a lot of folks are like why would you do this and spend all this time on this old truck and blah blah blah but uh, that's what I'm doing and it's my truck and I'm not buying a new one cuz new ones are expensive and I'm cheap. It's good for now. We need to, uh, tighten down this actuator I think it's flippy flopping everywhere causing a problem.

Okay, two more screws. these are I think the last of them. Again, they're 5 and 1/2 mm. Hey, does anybody know why the 55 exists cuz standard sizes don't match up to it and it's not a five and it's not a six.

Just wondering why we have a 5 1/2 mm uh, socket. Little curious? There we go. Plug that guy in right there. that's all set.

Very nice. All righty. So I have spent about 45 minutes getting all these wires put back into position. here.

They are routed down and around and through like you're tying your shoe properly. These ones, uh, on this side of those are ready to plug into the fuse box. This one is a ground that goes on in the firewall. Got our evaporator? We've got our heater core sealed up A small looking leak right there.

Temp sensors are plugged in, actuator plugged in. This temp sensor is plugged in. everybody's plugged in. So I Do believe that this section of Uh, this particular repair is all set and ready to roll.

So having said all that, uh I have nothing more to offer you on this particular video except for: I Thank you for watching this video. Certainly hope you enjoyed it if you did enjoy this. Please let me know in the comment section down below: Do not forget to tap that like button while you're down there And most importantly, have yourselves a fantastic day! See you guys later in the video End of Chevrolet Dashboard end of Transmission.