Front HVAC Housing Removal and Installation

REMOVAL

WARNING:
- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION.

- 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 ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Recover the refrigerant from the refrigerant system. Refer to: "Refrigerant : Service and Repair" Service and Repair
2. Drain the engine cooling system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" Service and Repair
3. Disconnect and isolate the battery negative cable.
4. Disconnect the liquid line and suction line from the expansion valve.
5. Disconnect the heater hoses from the heater core tubes.

Fig.13 Heater-A/C Unit Housing Studs:

6. Remove the four nuts that secure the heater-A/C unit housing studs to the engine compartment side of the dash panel.
7. Remove the instrument panel from the passenger compartment.Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

8. Remove the floor distribution duct from the heater-A/C unit housing.

Fig.14 Heater-A/C Unit Housing:

9. Remove the one screw that secures the heater-A/C unit housing bracket to the passenger compartment side of the dash panel.
10. Pull the heater-A/C unit housing rearward far enough for the mounting studs to clear the dash panel and remove the unit from the passenger compartment.

INSTALLATION

1. Position the heater-A/C unit housing against the dash panel in the passenger compartment with the four mounting studs located in their proper mounting holes in the dash panel.
2. Install and tighten the one screw that secures the heater-A/C unit housing bracket to the passenger compartment side of the dash panel. Tighten the screw to 3 Nm (26 in. lbs.).
3. Install and tighten the four nuts that secure the heater-A/C unit housing studs to the engine compartment side of the dash panel. Tighten the nuts to 7 Nm (62 in. lbs.).
4. Reinstall the floor distribution duct onto the heater-A/C unit housing.
5. Reinstall the instrument panel into the passenger compartment.Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

6. Reconnect the heater hoses to the heater core tubes.
7. Reconnect the suction line and liquid line to the expansion valve.
8. Reconnect the battery negative cable.
9. Refill the engine cooling system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" Service and Repair
10. Evacuate the refrigerant system. Refer to: "Refrigerant : Service and Repair" Service and Repair
11. Charge the refrigerant system.