Removal and Replacement

REMOVAL
The instrument panel must be removed in order to remove the heater-A/C Housing.

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

1. Using a refrigerant recovery machine, remove the refrigerant from the A/C system, if equipped.
2. Remove instrument panel from vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

3. Drain cooling system. Refer to: "Cooling System : Service and Repair" Service and Repair
4. Remove heater hoses at the dash panel. Place plugs in the heater core outlets to prevent coolant spillage during unit housing removal.
5. Unfasten coolant recovery container and set aside.
6. Remove suction line at expansion valve. Cap open refrigerant lines to prevent moisture and/or dirt from entering.
7. Remove expansion valve from evaporator, and cap fittings.
8. Remove rubber drain tube extension from condensation drain tube.

Fig.5 HVAC Vacuum Harness:

9. Disconnect the vacuum harness at the power brake booster.

Fig.6 HVAC Housing Defroster Duct:

10. Unsnap and remove the defroster duct.

Fig.7 Dash Panel Retaining Studs:

11. Remove three retaining nuts located in the engine compartment, on the dash panel.

Fig.6 Housing Screws:

12. Remove the right side retaining screw.
13. Remove remaining nut located on dash panel stud.
14. Disconnect the wiring connectors.
15. Remove assembly from the vehicle.

INSTALLATION

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

1. Position the housing in the vehicle.
2. Connect the wire harness connectors.
3. Install the nut on the dash panel stud.
4. Install the three retaining nuts on the engine compartment studs.
5. Snap the defrost duct in place.
6. Connect the vacuum harness at the brake booster.
7. Connect the rubber drain tube to the extension.
8. Install the expansion valve to the evaporator.
9. Remove the protective caps and connect the suction line to the expansion valve.
10. Position and install the coolant recovery container.
11. Install the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

12. Refill the cooling system. Refer to: "Cooling System : Service and Repair" Service and Repair
13. Evacuate the refrigerant system .
14. Recharge the refrigerant system.