Front HVAC Housing Installation

INSTALLATION

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system .

NOTE: If the A/C evaporator is being replaced, add 60 milliliters (2 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.

NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak.

NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage during this service procedure.





1. Position the HVAC housing (3) into the instrument panel with all of the mounting studs in their proper locations.

CAUTION: Make sure not to damage the stud mounting boss when install the HVAC housing retaining nuts. Hold the stud with vise grips or similar tool when tightening the nut onto the stud. Failure to follow this caution may result in damage to the HVAC housing.

2. Loosely install the three nuts (1) that secure the HVAC housing to the instrument panel Tighten the nuts to 5 Nm (44 in. lbs.).
3. Install the two bolts (2) that secure the HVAC housing to instrument panel. Tighten the bolt(s) to 3 Nm (26 in. lbs.).
4. Reconnect all wire harness connections to the HVAC housing.
5. Install the outer instrument panel ducts .
6. Install the two covers onto the top of the instrument panel.
7. Install the instrument panel assembly .




8. Remove the tape or plugs from the opened refrigerant line fittings and expansion valve and heater core ports. ports.
9. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the refrigerant line fittings. Use only the specified O-rings 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.

CAUTION: Use care when installing the A/C lines to the A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur.

10. Install the A/C liquid line (1) and the A/C suction line (2) onto the A/C expansion valve.
11. Install the nut (3) that secures the A/C liquid line and the A/C suction line to the A/C expansion valve. Tighten the nut to 6 Nm (53 in. lbs.).
12. Connect the heater hoses (4) to the heater core. Tighten the clamps securely.
13. Install the air cleaner housing Service and Repair.
14. Reconnect the negative battery cable.
15. If the heater core is being replaced, flush the cooling system Service and Repair.
16. Refill the engine cooling system Service and Repair.
17. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
18. Evacuate the refrigerant system .
19. Charge the refrigerant system .