HVAC Housing
DISASSEMBLYNOTE:
- The fresh air inlet housing must be removed from the vehicle for removal of the HVAC housing.
- LHD model shown in illustrations. RHD model similar.
1. Remove the HVAC housing assembly and place it on a workbench.
2. Remove the air distribution housing (3) from the HVAC housing (1).
3. Remove the air inlet housing (2) from the HVAC housing.
4. Remove the two screws (1) that secure the flange (2) to the front of the HVAC housing (3).
5. Remove the flange and the heater core tubes (4) from the HVAC housing.
6. Disconnect the HVAC wiring harness (1) from the evaporator temperature sensor (2), blower motor resistor or power module (3) (depending on application) and the blower motor (4).
7. Disengage the two HVAC wire harness retainers (5) from the blower motor and remove the blower motor from the HVAC housing.
8. Remove the blower motor resistor or power module, depending on application.
9. Remove the evaporator temperature sensor.
10. Remove the two bolts (1) that secure the A/C expansion valve (2) to the evaporator tube tapping block located within the foam seal (3).
11. Remove the A/C expansion valve from the evaporator tube tapping block and foam seal.
12. Remove the O-ring seals from the evaporator tube fittings and discard.
13. Install plugs in, or tape over the opened evaporator tube fittings and all expansion valve ports.
14. Remove the HVAC wiring harness (1).
15. Remove the ten screws (2) that secure the upper half of the HVAC housing (3) to the lower half of the HVAC housing (4).
16. Separate the two halves of the HVAC housing.
17. Carefully lift the A/C evaporator (1) and foam seal (2) out of the lower half of the HVAC housing (3).
18. If required, remove the foam seal from the tapping block of the A/C evaporator. If the seal is deformed or damaged, it must be replaced.
ASSEMBLY
NOTE: LHD model shown in illustrations. RHD model similar.
1. If removed, install the foam seal (2) over the tapping block of the A/C evaporator (1). If the seal is deformed or damaged, it must be replaced.
2. Install the A/C evaporator into the lower half of the HVAC housing (3). 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.
3. Install the upper half of the HVAC housing (3) onto the lower half of the HVAC housing (4).
4. Install the screws (2) that secure the two halves of the HVAC housing together. Tighten the screws to 2.2 N.m (20 in lbs.).
5. Install the HVAC wiring harness (1). Make sure the harness is routed through all wiring retainers.
6. Remove the tape or plugs from the evaporator tube fittings and all of the expansion valve ports.
7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator tube fittings. Use only the specified O-rings 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.
8. Install the A/C expansion valve (2) onto the evaporator tube tapping block located within the foam seal (3).
9. Install the two bolts (1) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 N.m (97 in. lbs.).
10. Install the evaporator temperature sensor (2).
11. Install the blower motor resistor or power module (3), depending on application.
12. Install the blower motor (4).
13. Connect the HVAC wire harness (1) to the evaporator temperature sensor, blower motor resistor or power module (depending on application) and the blower motor.
14. Install the two HVAC wire harness retainers (5) onto the blower motor.
15. Install the heater core tubes (4) and the flange (2) to the front of the HVAC housing (3).
16. Install the two screws (1) that secure the flange to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).
17. Install the air inlet housing (2) onto the HVAC housing (1).
18. Install the air distribution housing (3) onto the HVAC housing.
19. Install the HVAC housing assembly.