HVAC Housing

HOUSING-HVAC

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

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





1. Remove the HVAC housing assembly and place it on a workbench HVAC Housing - Removal.
2. Remove the air distribution housing (2) from the HVAC housing (1) HVAC Housing - Removal.
3. Remove the air inlet housing (3) from the HVAC housing HVAC Housing - Removal.





4. Remove the three screws (1) that secure the blower motor (3) and the wire lead bracket (2), if equipped, to the bottom of the HVAC housing (4) and remove the blower motor.
5. Remove the two screws (5) that secure the blower motor resistor or power module (6), depending on application, to the bottom of the HVAC housing and remove the resistor or module.





6. Using needle nose pliers (1), disengage the two retaining tabs (2) that secure the evaporator temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor.






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

7. Remove the two bolts that secure the A/C expansion valve (6) to the A/C evaporator and remove the valve A/C Expansion Valve - Removal.
8. Remove and discard the O-ring seals and install plugs in, or tape over the opened expansion valve and evaporator tube ports.
9. Remove the foam seal and plastic flange (2) from the front of the two halves of the HVAC housing (4). Carefully release the four retaining tabs located at the back of the flange and pull the flange off of the evaporator tubes. If the seal or flange is deformed or damaged, it must be replaced.
10. Remove any residual sealer from the flange area at the front of the two halves of the HVAC housing.
11. Remove the six screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together.
12. Disengage the eight plastic retaining tabs (1) that secure the two halves of the HVAC housing together and separate the housing.






NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.

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