Housing Assembly HVAC: Service and Repair

PLENUM CHAMBER

Removal and Installation

NOTE:
- If an evaporator core leak is suspected, the evaporator must be vacuum leak tested before it is removed from the vehicle.
- Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. Recover the refrigerant.
2. Drain the engine coolant.
3. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, Removal and Installation

4. Remove the rear footwell duct.







5. Disconnect the powertrain control module (PCM) electrical connectors.







6. Remove the bolts and remove the PCM.







7. Remove the bolts and remove the PCM bracket.







8. Disconnect the quick-disconnect fittings at the heater core.







9. Disconnect the fittings at the thermostatic expansion valve.
- Discard the O-ring seals.







10. Disconnect the A/C fittings at the evaporator core.
- Discard the O-ring seals.







11. Remove the nut.







12. Remove the nut.







13. Remove the nut.







14. Disconnect the two vacuum lines at the top of the plenum chamber.







15. Remove the screws and position the wire harness aside.







16. Remove the nuts.







17. Remove the nut.







18. Remove the nut and remove the plenum chamber.
19. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
- Clean and lubricate the coolant hoses with plain water only if needed.

20. Refill the engine coolant level.
21. Evacuate, leak test and charge the refrigerant system.