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Front HVAC Housing Installation







HOUSING-HVAC

NOTE: Replacement of the refrigerant line seals is required anytime a refrigerant line or expansion valve is disconnected or removed. Failure to replace the rubber and metal dual-plane seals may result in a refrigerant system leak.





1. Install the defroster duct to the top of the HVAC air distribution housingFront Defroster Ducts - Installation.
2. Position the HVAC housing (3) into the instrument panel support (2)
3. Loosely install the bolt (1) that secures the passenger side end of the HVAC housing to the underside of the instrument panel support.




4. Loosely install the bolt (1) that secures the passenger side of the HVAC air distribution housing (4) to the underside of the instrument panel support (3).
5. Connect the instrument panel wire harness to the HVAC wire harness connector (2).




6. Loosely install the bolt (1) that secures the driver side of the HVAC air distribution housing (2) to the underside of the instrument panel support (3).




7. Loosely install the bolt (1) that secures the HVAC housing (2) to the front of the instrument panel support (3).
8. Tighten all of the bolts that secure the HVAC housing to the instrument panel support to 3 Nm (27 in. lbs.).




9. Install the two screws (1) that secure the defroster duct (2) to the top of the instrument panel cover (3). Tighten the screws to 2 Nm (17 in. lbs.).
10. Position the instrument panel and HVAC housing into the vehicle as an assembly. Make sure to align the condensate drain with the drain tube located in the center of the floor panel and to fully engage the floor distribution ducts to the outlets in the bottom of the HVAC housing.
11. Install the instrument panel. Service and Repair




NOTE: Illustration shown with instrument panel removed for clarity.

12. Install the bolt (1) that secures the HVAC air inlet housing (3) to the passenger side of the dash panel (2). Tighten the bolt to 3 Nm (27 in. lbs.).
13. Install the defroster grille onto the top of the instrument panel.




14. Install the bolt (1) that secures the HVAC housing to the engine compartment side of the dash panel (2). Tighten the bolt to 3 Nm (27 in. lbs.).




15. Remove the tape or plugs from the opened refrigerant line fittings and expansion valve and heater core ports. ports.
16. Lubricate new dual-plane seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified 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.

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. Service and Repair

17. Connect the A/C suction line (1) and the A/C liquid line (5) to the A/C expansion valve (2).
18. Install the nut (3) that secures the A/C suction and liquid lines to the A/C expansion valve. Tighten the nut to 23 Nm (17 ft. lbs.).
19. Connect the heater hoses (4) to the heater core. Tighten the clamps securely.
20. Reconnect the negative battery cable.
21. If the heater core is being replaced, flush the cooling systemService and Repair.
22. Refill the engine cooling systemService and Repair.
23. Evacuate the refrigerant systemRefrigerant System Evacuate.
24. Charge the refrigerant systemRefrigerant System Charge.
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