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HVAC Housing







HVAC HOUSING

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system Refrigerant Oil Level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Level.

NOTE: If only the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.





1. Carefully install the A/C evaporator (3) into the upper half of the HVAC housing (2).
2. Install the foam seal (1) onto the tubes of the A/C evaporator.




3. Install the defroster-air doors (1) into the lower half of the HVAC housing (2).
4. Align the actuator coupler (3) with the defroster-air door pivot shaft and install the coupler into side of the HVAC housing. Be sure to install the coupler with the coupler arm located between the two stop tabs on the HVAC housing.




5. Install the blend-air doors (1) into each of the two blend door plates (2).
6. Align the actuator coupler (3) with each blend-air door pivot shaft and install the coupler into side of each blend door plate. Be sure to install each coupler with the coupler arm located between the two stop tabs on each blend door plate.




7. Position the lower blend door assembly (2) into the lower half of the HVAC housing (3) and fully engage the three retaining tabs (1).
8. Position the upper blend door assembly into the upper half of the HVAC housing and fully engage the three retaining tabs.




NOTE: Route the wire lead for the evaporator temperature sensor into the opening located on the upper half of the HVAC housing prior to installing the lower half of the HVAC housing.

9. Position the two halves of the HVAC housing together (3).
10. Install the fifteen screws (6) that secure the two housing halves together. Tighten the screws to 1.1 Nm (10 in. lbs.).
11. Install the foam seal (4) onto the evaporator condensate drain tube (5).
12. Connect the linkage rod (1) to the two blend-air door levers (2) located on the back of the HVAC housing.




13. Position the front floor distribution duct (1) to the bottom of the HVAC housing (2).
14. Install the screws (3) that secure the front floor distribution duct to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.).




15. Carefully install the heater core (3) into the front of the HVAC housing.
16. Position the heater core tube bracket (2) onto the HVAC housing.
17. Install the two screws (1) that secure the heater core bracket to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.).
18. If equipped with the dual zone heating-A/C system, install the linkage rod (4).
19. Install the foam seal onto the heater core tubes.




20. Install the panel/floor-air doors (1) into the panel/floor door plate (2).
21. Align the actuator coupler (3) with the panel/floor-air door pivot shaft and install the coupler into side of the panel/floor door plate. Be sure to install the coupler with the coupler arm located between the two stop tabs on the door plate.




22. Position the panel/floor door assembly (2) onto the top of the HVAC housing (3).

NOTE: Install the two door springs onto the retaining screws prior to installation.

23. Install the three screws (2) that secure the door assembly to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.).




24. Position the panel/floor door outlet (2) onto the top of the HVAC housing (3) and fully engage the two retaining tabs (3).
25. Install the two screws (1) that secure the panel/floor door outlet to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.).




26. Install the air inlet housing (3) onto the top of the HVAC housing (4) HVAC Housing - Installation .
27. Install the HVAC wire harness (1) onto the HVAC housing. Make sure the wires are routed through all wiring retainers.
28. Install the evaporator temperature sensor (2) into the opening in the top of the HVAC housing. Make sure the sensor is fully engage to the housing.
29. Connect the HVAC wire harness to the evaporator temperature sensor.




30. Position the blower motor resistor (7) and the blower motor (2) into the bottom of the HVAC housing (5).
31. Install the screws (4) that secure the blower motor to the HVAC housing. Tighten the screws to 1.7 Nm (15 in. lbs.).
32. Install the screws (6) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.).
33. Connect the HVAC wire harness connectors (1 and 3) to blower motor resistor and the blower motor.




34. Position the recirculation door actuator (3) onto the air inlet housing (4) and install the retaining screws. Tighten the screws to 1.1 Nm (10 in. lbs.)
35. Position the mode door actuators (1) and the blend door actuators (2) onto the HVAC housing (5) and install the retaining screws. Tighten the screws to 1.1 Nm (10 in. lbs.).
36. Connect the HVAC wire harness connectors to the actuators.
37. Install the HVAC housing HVAC Housing - Installation .
38. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Level . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
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