HVAC Housing

SPECIAL SERVICE TOOL(S) REQUIRED

Removal


1. Disconnect battery ground cable.

2. Discharge refrigerant from A/C system. Observe all safety precautions. Service and Repair

3. Disconnect the electrical hard-shell connectors from the blower motor, the heater blower motor switch resistor and the A/C cycling switch.

4. Disconnect the vacuum line (part of A/C blower motor feed extension from the A/C vacuum check valve.

5. Disconnect the vacuum line (part of the vacuum assembly) from the vacuum source on the engine intake manifold; then remove the line from the routing channel.

6. Disconnect the condenser to evaporator tube from the inlet tube and cap the openings to prevent the entry of dirt and moisture.

7. Disconnect the A/C manifold and tube from the suction accumulator/drier.

8. Remove the speed control module from the fender.

9. Remove the coolant recovery reservoir.

10. Remove the solenoid box cover, if so equipped, by removing three bolts fastened through the fender liner. Remove the air cleaner and A/C vacuum reservoir tank and bracket,if so equipped.

11. Remove three nuts from the engine compartment side of the A/C evaporator housing and one nut from the passenger compartment side of the A/C evaporator housing.

12. Remove A/C evaporator housing from the vehicle.

Installation

1. Position the A/C evaporator housing to the dash panel and install three retaining nuts in the A/C evaporator housing on the engine compartment side and one from the passenger compartment side of the A/C evaporator housing.

2. Install the air cleaner, speed control and coolant recovery reservoir.

3. Using a new O-ring lubricated with clean refrigerant oil, connect the condenser to evaporator tube to the inlet tube. Tighten the connection to 21-27 Nm (15-20 lb-ft) using a backup wrench.

4. Connect the A/C manifold and tube to the suction accumulator/drier outlet tube after checking for a missing or damaged garter spring and/or repairing or replacing the spring. Install two new specified (special material) O-rings, lubricated with clean refrigerant oil onto the coupling male fitting.

5. Connect the vacuum line to the A/C vacuum check valve

6. Connect the vacuum line (part of A/C vacuum reservoir tank and bracket to the source on the engine intake manifold and route the same as when removed.

7. Connect the electrical hard-shell connectors to the heater blower motor switch resistor, the A/C cycling switch , and the blower motor.

8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

Reconnect battery ground cable.

9. Leak test, evacuate and charge the system. Service and Repair