Removal and Replacement

REMOVAL
The HVAC housing must be removed from the vehicle and the two halves of the housing separated for service access of the heater core, evaporator and the mode, recirculation and blend doors.

WARNING:
- ON VEHICLES EQUIPPED WITH AIR-BAGS, 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.
- REVIEW THE WARNINGS AND CAUTIONS IN PLUMBING BEFORE PERFORMING THE FOLLOWING OPERATION.

1. Recover the refrigerant from the refrigerant system.
2. Partially drain the engine cooling system.
3. Disconnect and isolate the battery negative cable.
4. Remove the coolant recovery container.
5. Remove the screw that secures the accumulator mounting bracket to the body.
6. Remove the two bolts securing the accumulator tubes to the evaporator terminal block and disconnect the tubes from the terminal block.
7. Remove the seals from the refrigerant lines fittings and discard.
8. Install plugs in, or tape over all of the opened refrigerant line fittings and evaporator tubes.

A/C Vacuum Line - LHD Shown, RHD Typical:

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

Dash Panel - LHD Shown, RHD Typical:

10. Remove the rubber drain tube extension from the condensation drain tube.
11. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal.
12. Remove three HVAC housing retaining nuts located on the dash panel in the engine compartment.
13. Remove the instrument panel from vehicle.
14. Remove the mode door and temperature control cables from the mode door and blend-air door levers and the HVAC housing.
15. Remove the defroster and floor distribution ducts from the HVAC housing.
16. Disconnect the wire harness connectors.

Housing Screws-LHD Shown, RHD Typical:

17. Remove the outboard HVAC housing retaining screw located in the passenger compartment.
18. Remove the remaining nut located on the dash panel stud.

NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores.

19. Remove the HVAC housing from the vehicle.

INSTALLATION

NOTE: High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free.

1. Position the HVAC housing to the dash panel.
2. Install the nut onto the dash panel stud. Tighten the nut to 4.5 Nm (40 in. lbs.).
3. Install the outboard HVAC housing retaining bolt. Tighten the bolt to 4.5 Nm (40 in. lbs.).
4. Connect the wire harness connectors.
5. Install the defroster and floor distribution ducts onto the HVAC housing.
6. Loosely install the mode door and temperature control cables to the mode door and blend-air door levers and to the HVAC housing .
7. Install the instrument panel and adjust the mode and temperature control cables.
8. Install the three HVAC housing retaining nuts onto the housing studs in the engine compartment. Tighten the nuts to 4.5 Nm (40 in. lbs.).
9. Unplug or remove the tape from the heater core hoses and tubes.
10. Connect the heater hoses to the heater core tubes and install the heater hose clamps.
11. Install the rubber drain tube extension onto the condensation drain tube.
12. Connect the vacuum harness at the brake booster.
13. Unplug or remove the tape from the opened refrigerant line fittings.
14. Lubricate two new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fittings.
15. Connect the accumulator tubes to the evaporator terminal block.
16. Install the two bolts securing the refrigerant lines to the evaporator tube tapping plate. Tighten the bolts to 10 Nm (88 in. lbs.).
17. Install the bolt securing the accumulator mounting bracket. Tighten the bolt to 11 Nm (97 in. lbs.).
18. Position and install the coolant recovery container.
19. Reconnect the negative battery cable.
20. Refill the engine cooling system.
21. Evacuate the refrigerant system .
22. Charge the refrigerant system .
23. Start the engine and check for proper operation of the heating and air conditioning systems as equipped.