Front HVAC Housing Removal and Installation

HVAC HOUSING

REMOVAL

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH.

NOTE: The HVAC housing must be removed from the vehicle and the two halves of the housing separated for service of the heater core, A/C evaporator, blend door and each of the various mode doors.

1. Disconnect and isolate the negative battery cable.
2. Remove the instrument panel.
3. If the vehicle is not equipped with A/C, go to Step 6. If the vehicle is equipped with A/C, recover the refrigerant from the refrigerant system.
4. Disconnect the A/C liquid and suction lines from the A/C evaporator and remove and discard the O-ring seals.
5. Install plugs in, or tape over the opened suction and liquid line fittings and both evaporator tubes.
6. Drain the engine cooling system.
7. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes.
8. Disconnect the HVAC system vacuum supply line connector from the tee fitting near the heater core tubes.

HVAC Housing - LHD Shown, RHD Similar:

9. Remove the five nuts that secure the HVAC housing to the dash panel in the engine compartment. If necessary, loosen the battery hold-downs and reposition the battery for additional access.
10. Remove the two push-nuts that secure the defroster duct to the dash panel in the passenger compartment and remove the duct.
11. Remove the bolt that secures the HVAC housing to the bracket located on the dash panel in the passenger compartment.
12. Remove the HVAC housing from inside the vehicle taking care not to allow any remaining coolant to drain on the vehicles interior.

INSTALLATION

NOTE: Use only the specified O-rings as they are made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor in the vehicle.

1. Position the HVAC housing to the dash panel. Be certain that the evaporator condensate drain tube and the housing mounting studs are inserted into their correct mounting holes.
2. Install the bolt that secures the HVAC housing to the bracket located on the dash panel in the passenger compartment. Tighten the bolt to 3 N.m (27 in. lbs.).
3. Install the defroster duct onto the top of the HVAC housing.
4. Install the two push-nuts that secure the defroster duct to the dash panel in the passenger compartment.
5. Install the five nuts that secure the HVAC housing to the dash panel in the engine compartment. Tighten the nuts to 6 N.m (53 in. lbs.).
6. If the battery was repositioned during the removal procedure, position the battery and tighten the hold-downs.
7. Connect the HVAC system vacuum supply line connector to the tee fitting near the heater core tubes.
8. Unplug or remove the tape from the heater core tubes and connect the heater hoses to the heater core tubes.
9. If the vehicle is not equipped with A/C, go to Step 15. If the vehicle is equipped with A/C, unplug or remove the tape from the liquid and suction line fittings and both evaporator tubes.
10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the liquid and suction line fittings.
11. Connect the A/C liquid and suction lines to the A/C evaporator.
12. Install the instrument panel.
13. Evacuate the refrigerant system.
15. Reconnect the negative battery cable.
16. If the heater core is being replaced,flush the cooling system.
17. Refill the engine cooling system.