Manual A/C

Heater/Air Distributor Case Assembly

Removal Procedure




1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
3. Remove the nuts that secure the air conditioning (A/C) suction hose and liquid evaporator pipe blocks at the bulkhead.




4. Loosen the A/C suction hose clamp bolt. Loosen the liquid evaporator pipe clamp bolt.
5. Loosen the A/C suction hose and the liquid evaporator pipe clamps to allow movement of the tubes.
6. Pull the A/C suction hose and liquid evaporator pipe from the evaporator inlet.
7. Remove the evaporator drain hose.




8. Remove the instrument panel carrier assembly. Refer to Section 9E, Instrumentation/Driver Information.
9. Twist the vacuum hose connection and remove it from beside the heater hoses.




10. Compress the heater hose clamps at the bulkhead and slide the clamps toward the engine.
11. Remove the two heater hoses from the core pipes at the bulkhead.
12. Remove the screws that secure the heater/air distributor case assembly to the bulkhead on either side of the heater hoses.




13. Remove the heater/air distributor case screw from above the fuel filter on the engine compartment side of the bulkhead.




14. Have an assistant support the heater/air distributor case from inside the vehicle.
15. Remove the heater/air distributor case screws from the connecting block mount on the engine compartment side of the bulkhead.The heater/air distributor case assembly will start to drop.

NOTE: To avoid damaging the heater core pipes,move the heater/air distributor case assembly straight away from the vehicle until the pipes are free from their openings in the bulkhead.

16. Remove the heater/air distributor case assembly.

Installation Procedures




1. Position the heater/air distributor case assembly in the vehicle.

NOTE: To avoid damaging the vehicle, make sure the heater core pipes do not contact the bulkhead opening.

2. Slowly raise the heater/air distributor case assembly into position against the bulkhead and hold it there while the screws are installed and tightened from the engine side of the bulkhead.
3. Install the heater/air distributor case assembly screws at the connecting block mount on the engine compartment side of the bulkhead.

Tighten
Tighten the heater/air distributor case assembly screws to 8 N.m (71 lb-in).




4. Align and install the heater/air distributor case assembly screw above the fuel filter.

Tighten
Tighten the heater/air distributor case assembly screw to 8 N.m(71 lb-in).

5. Replace the fuel filter into its mounting clamp.




6. Install the heater/air distributor case assembly screws on either side of the heater core pipes.

Tighten
Tighten the heater/air distributor case assembly screws to 8 N.m (71 lb-in).

7. Install the two heater hoses.
8. Slide the heater hose clamps into position.
9. Install the vacuum hose.




10. Install the instrument panel carrier assembly. Refer to Instrumentation/Driver In formation.




11. Install two new O-rings onto the A/C suction hose and the liquid evaporator pipe at the bulkhead in the engine compartment.

IMPORTANT: Do not try to verify the operation of the system until you have installed and recharged the A/C system.

12. Install the heater/air distributor case into the vehicle. Refer to Heating and Ventilation System.
13. Install the A/C suction hose and the liquid evaporator pipes onto the evaporator flange connecting block studs.
14. Secure the liquid evaporator pipe and the suction hose to the evaporator flange with the nuts.

Tighten
Tighten the suction hose connecting block retaining nuts to 10 N.m (89 lb-in).




15. Install the A/C suction hose clamp with the bolt.

Tighten
Tighten the suction hose clamp bolt to 10 N.m (89 lb-in).

16. Install the liquid evaporator pipe clamp with the bolt.

Tighten
Tighten the liquid evaporator pipe clamp bolt to 5 N.m (44 lb-in).

17. Install the evaporator drain hose.
18. Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
19. Operate the HVAC control to verify the proper function of the heating and the cooling systems.