Front

ASSEMBLY
1. Install the A/C evaporator into the lower half of the HVAC housing. Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and that the insulator around the A/C evaporator is properly installed.
2. Install the upper half of the HVAC housing onto the lower half of the HVAC housing.
3. Install the thirteen screws that secure the two halves of the HVAC housing together. Tighten the screws to 2 N.m (17 in lbs.).
4. If removed, install the support bracket and the two retaining screws. Tighten the screws to 2 N.m (17 in lbs.).
5. If removed, install the blower motor resistor or power module (depending on application) and the two retaining screws. Tighten the screws to 2 N.m (17 in lbs.).
6. If removed, install the blower motor and the three retaining screws. Tighten the screws to 2 N.m (17 in lbs.).
7. Install the HVAC wiring harness. Make sure the harness is routed through all wiring retainers.
8. Engage the HVAC wire harness into the routing clips on the HVAC housing.
9. On RS models, install the evaporator temperature sensor into the top of the HVAC housing and connect the HVAC wiring harness to the sensor.
10. Connect the HVAC wire harness to the blower motor resistor or power module (depending on application).
11. Install the A/C expansion valve.
12. Install the air inlet housing onto the HVAC housing.
13. Install the air distribution housing onto the HVAC housing.
14. Install the HVAC housing into the vehicle.

DISASSEMBLY

NOTE:
- The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.
- LHD model shown in illustrations. RHD model similar.

1. Remove the HVAC housing from the vehicle and place it on a workbench.

HVAC Housing Assembly:

2. Remove the air distribution housing from the HVAC housing.
3. Remove the air inlet housing from the HVAC housing.
4. Remove the A/C expansion valve from the A/C evaporator.

HVAC Housing:

5. Disconnect the HVAC wiring harness from the blower motor resistor or power module (depending on application).
6. On RS models, disconnect the HVAC wiring harness from the evaporator temperature sensor located on the top of the HVAC housing and remove the sensor from the housing.
7. Disengage the HVAC wire harness from the routing clips on the HVAC housing and remove the wire harness from the housing.
8. If required, remove three screws that secure the blower motor to the HVAC housing and remove the blower motor.
9. If required, remove two screws that secure the blower motor resistor or power module (depending on application) to the HVAC housing and remove the resistor or module.
10. If required, remove two screws that secure the support bracket to the HVAC housing and remove the bracket.
11. Remove the thirteen screws that secure the upper HVAC housing half to the lower half of the HVAC housing.
12. Separate the two halves of the HVAC housing.
13. Carefully lift the A/C evaporator and insulator out of the lower half of the HVAC housing.