HVAC Housing

HOUSING-HVAC

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.






NOTE: Make sure that the foam insulator is properly positioned around the A/C evaporator and in the HVAC housing.

1. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3).





2. Install the two halves of the HVAC housing (4) together and engage the eight plastic retaining tabs (1). Make sure the retaining tabs are fully engaged.
3. Install the six screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together. Tighten the screws to 1.2 Nm (10 in lbs.). Make sure the metal clips are fully engaged to the housing halves.
4. Install a bead of silicone sealer around the flange area at the front of the HVAC housing.

NOTE: If the foam seal or plastic flange is deformed or damaged, it must be replaced.

5. Install the plastic flange and foam seal (2) over the evaporator tubes and onto the front of the HVAC housing. Make sure the four flange retaining tabs are fully engaged to the housing.
6. Remove the tape or plugs from the expansion valve and evaporator ports.
7. Lubricate new O-ring seals with clean refrigerant oil and install them onto the evaporator tube fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
8. Install the A/C expansion valve (6) and the two retaining bolts. Tighten the bolts to 11 Nm (97 in. lbs.) A/C Expansion Valve - Installation.





9. Install the evaporator temperature sensor (1) into the driver side of the HVAC housing (2). Make sure the retaining tabs (3) are fully engaged to the housing.





10. Position the blower motor (3) into the bottom of the HVAC housing (4).
11. Install the wire lead bracket (2), if equipped, and the three screws (1) that secure the blower motor to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.).
12. Position the blower motor resistor or power module (6), depending on application, into the HVAC housing.
13. Install the two screws (5) that secure the blower motor resistor or power module to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.).





14. Install the air inlet housing (3) onto the HVAC housing (1) HVAC Housing - Installation.
15. Install the air distribution housing (2) onto the HVAC housing HVAC Housing - Installation.

NOTE: If the heater core is being replaced, flush the cooling system Service and Repair .

16. Install the HVAC housing assembly HVAC Housing - Installation.