Front HVAC Housing Removal and Installation

REMOVAL

WARNING:
- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.
- 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 AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH.

NOTE:
- The HVAC housing must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator.
- Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure.
- LHD model shown in illustrations. RHD model similar.

1. Recover the refrigerant from the refrigerant system.
2. Drain the engine cooling system.
3. Disconnect and isolate the negative battery cable.
4. Disconnect the A/C liquid and suction lines from the A/C expansion valve.
5. Disconnect the heater hoses from the heater core.

HVAC Housing Engine Compartment:

6. Remove the three nuts that secure the HVAC housing to the engine compartment side of the dash panel.
7. Remove the instrument panel from the passenger compartment.

HVAC Housing Passenger Compartment:

8. Remove the nut and bolt that secure the HVAC housing to the passenger compartment side of the dash panel.
9. Pull the HVAC housing rearward to clear the dash panel and remove the HVAC housing from the passenger compartment.
10. If required, disassemble the HVAC housing.

INSTALLATION

NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator.

1. Position the HVAC housing against the dash panel in the passenger compartment with the three mounting studs located in their proper holes. Make sure that the condensate drain tube protrudes through its opening.
2. Loosely install the nut and bolt that secures the HVAC housing to the passenger compartment side of the dash panel.
3. Install the three nuts that secure the HVAC housing to the engine compartment side of the dash panel. Tighten the nuts to 7 N.m (62 in. lbs.).
4. Tighten the nut and bolt that secures the HVAC housing to the passenger compartment side of the dash panel to 3 N.m (27 in. lbs.).
5. Install the instrument panel.
6. Connect the heater hoses to the heater core.
7. Connect the A/C suction and liquid lines to the A/C expansion valve.
8. Reconnect the negative battery cable.
9. If the heater core is being replaced, flush the cooling system.
10. Refill the engine cooling system.
11. Evacuate the refrigerant system.
12. Charge the refrigerant system.
13. Calibrate the A/C-heater control.