HVAC Housing - Removal and Installation
HOUSING-HVACNOTE: LHD model shown in illustration. RHD model similar.
REMOVAL
WARNING:
- ON VEHICLES EQUIPPED WITH AIRBAGS, 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 OR DEATH.
- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION AND FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.
NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, air intake housing and the mode-air and blend-air doors.
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system.
3. Partially drain the engine cooling system.
4. Remove the air filter intake tube and air filter housing cover.
5. Remove the coolant recovery container.
6. Disconnect the refrigerant lines from the A/C evaporator (2) the A/C accumulator and remove and discard the O-ring seals.
7. Install plugs in, or tape over all of the opened refrigerant line fittings and the evaporator and accumulator ports.
8. Remove the condensation drain tube (3).
9. Disconnect the heater hoses (5) from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal.
10. Remove three HVAC housing retaining nuts (6) located on the engine compartment side of the dash panel (4).
NOTE: LHD model shown in illustration. RHD model similar.
11. Remove the instrument panel.
12. Remove the right rear floor duct.
13. Position the dash panel insulator (1) out of the way and remove the bolt (3) that secures the HVAC housing (4) to the passenger compartment side of the dash panel (2).
14. Remove the bolt (5) that secures the HVAC housing to the floor bracket (6).
NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores.
15. Pull the HVAC housing rearward so that the mounting studs and condensate drain clear the dash panel and remove the HVAC housing assembly from the passenger compartment.
INSTALLATION
1. Position the HVAC housing assembly to the dash panel (2). Be certain that the condensate drain and the housing mounting studs are inserted into their correct locations.
2. Install the bolt (3) that secures the air inlet housing (4) to the passenger compartment side of dash panel. Tighten the bolt to 4.5 N.m (40 in. lbs.).
3. Install the bolt (5) that secures the HVAC housing (7) to the floor bracket (6). Tighten the bolt to 4.5 N.m (40 in. lbs.).
4. Install the right rear floor duct.
5. Reposition the dash panel insulator (1) and install the instrument panel.
NOTE: LHD model shown in illustration. RHD model similar.
6. Install the three nuts(6) that secure the HVAC housing to the engine compartment side of the dash panel (4). Tighten the nuts to 4.5 N.m (40 in. lbs.).
7. Remove the previously installed plugs or caps and connect the heater hoses (5) to the heater core tubes.
8. Install the condensation drain tube (3).
9. Remove the previously installed plugs or caps and connect the refrigerant lines to the A/C evaporator (2) and A/C accumulator using new O-ring seals.
10. Install the coolant recovery container.
11. Install the air filter housing and air inlet tube.
12. Reconnect the negative battery cable.
13. If the heater core is being replaced, flush the cooling system.
14. Refill the engine cooling system.
15. Evacuate the refrigerant system.
16. Charge the refrigerant system.