Overhaul

Front HVAC Housing


Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery 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 may result in accidental airbag deployment and possible serious or fatal injury.


Review the applicable warnings and cautions for this system before performing the following operation.

• The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.

Disassembling






- Remove the HVAC housing and place it on a workbench. Refer to => [ Front HVAC Housing ] Front HVAC Housing.

- Remove the air inlet housing (2) from the HVAC housing (1). Refer to => [ Front Air Inlet Housing ] Front Air Inlet Housing.

- Remove the air distribution housing (3) from the HVAC housing. Refer to => [ Front Air Distribution Housing ] Front Air Distribution Housing.






- Disconnect the HVAC wire harness (2) from the blower motor (3), blower motor resistor or power module (depending on application) (4) and the evaporator temperature sensor (5) and remove the harness from the HVAC housing (1).

- Remove the blower motor from the bottom of the HVAC housing. Refer to => [ Front Blower Motor ] Service and Repair.

- Disengage the retaining tabs that secure the blower motor resistor or power module (depending on application) to the HVAC housing and remove the resistor. Refer to => [ Front Blower Motor Resistor ] Service and Repair or power module, refer to => [ Front Blower Motor Power Module ] Service and Repair.

- Remove the evaporator temperature sensor from the HVAC housing. Refer to => [ Front Evaporator Temperature Sensor ] Service and Repair.






- Remove the eleven screws (2) that secure the two halves of the HVAC housing together (1 and 3) and separate the housing.






- Carefully remove the A/C evaporator (1) and its insulator (2) from the HVAC housing (3).

Assembling

• If the A/C evaporator is being replaced, add 50 milliliters (1.7 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

• Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and that the insulator is properly positioned.








• If the foam insulator for the A/C evaporator is deformed or damaged, it must be replaced.

- Install the A/C evaporator (2) into the HVAC housing (3). Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and that the insulator (1) around the A/C evaporator is properly positioned.






- Install the two halves of the HVAC housing (1 and 3) together and install the eleven retaining screws (2). Tighten the screws to 1.2 Nm (10 in lbs).






- Install the evaporator temperature sensor (5) to the HVAC housing (1). Refer to => [ Front Evaporator Temperature Sensor ] Service and Repair. Make sure the retaining tabs are fully engaged.

- Install the blower motor resistor. Refer to => [ Front Blower Motor Resistor ] Service and Repair or power module, refer to => [ Front Blower Motor Power Module ] Service and Repair (depending on application) (4) to the HVAC housing. Make sure the retaining tabs are fully engaged.

- Install the blower motor (3) to the HVAC housing and install the retaining screw. Refer to => [ Front Blower Motor ] Service and Repair. Make sure the blower motor locking feature is fully engaged and tighten the screw to 1.2 Nm (10 in lbs).

- Install the HVAC wire harness (2) and connect it to the blower motor, blower motor resistor or power module (depending on application) and the evaporator temperature sensor.






- Install the air inlet housing (2) onto the HVAC housing (1). Refer to => [ Front Air Inlet Housing ] Front Air Inlet Housing.

- Install the air distribution housing (3) onto the HVAC housing. Refer to => [ Front Air Distribution Housing ] Front Air Distribution Housing.

• If the heater core is being replaced, flush the cooling system.

- Install the HVAC housing. Refer to => [ Front HVAC Housing ] Front HVAC Housing.