Removal and Replacement

REMOVAL
The instrument panel must be removed in order to remove the Unit Housing.

WARNING: THE R-134a REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM.

1. Disconnect battery negative remote cable. This must be done to prevent accidental airbag deployment.

WARNING:
- AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE.
- R-134a SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR/R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE.

2. Using an A/C recovery unit, remove all R-134a refrigerant from the A/C system.
3. Drain the engine cooling system.
4. Remove air cleaner snorkel and filter housing.
5. Disconnect heater hoses at the dash panel. Plug the heater core inlet and outlet tubes to prevent antifreeze from spilling on the vehicle interior during removal. If an appropriate plug cannot be found pull back carpet and use caution when removing unit. Keep the heater tubes elevated to prevent spillage of coolant.
6. Remove A/C lines from expansion valve. After removing lines cap the expansion valve openings and the A/C hose openings. This will prevent any dirt or moisture from entering the refrigerant system during servicing.
7. Remove two screws attaching the expansion valve and remove valve.

CAUTION: The lubricant used in this air conditioning system absorbs moisture readily (similar to brake fluid). Do not leave any portion of the system open for extended periods of time.

8. Remove instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, Instrument Panel Assembly

Fig. 2 Bulkhead Panel Studs:

9. Remove bolts securing Heater-A/C housing to cowl.

Fig. 3 Unit Housing Removal:

10. Remove housing from the vehicle.

INSTALLATION
1. Position the heater-A/C housing on the cowl.
2. Install the unit housing retaining bolts.
3. Install the instrument panel.
4. Install the expansion valve.
5. Connect the A/C lines to the expansion valve. Refer to Heating and Air Conditioning installation.
6. Connect the heater hoses.
7. Install the air cleaner snorkel and filter housing.
8. Refill the engine cooling system.
9. Recharge the A/C system.
10. Connect the battery negative cable.