Removal and Replacement

REMOVAL

WARNING: 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 AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

The heater-A/C housing assembly must be removed from the vehicle and the two halves of the housing separated for service access of the heater core, evaporator coil, blend-air door, and each of the various mode control doors.
1. Disconnect and isolate the battery negative cable.
2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

3. If the vehicle is not equipped with air conditioning, go to Step 6. If the vehicle is equipped with air conditioning, recover the refrigerant from the refrigerant system. Refer to Heating and Air Conditioning/Service and Repair. Service and Repair
4. Disconnect the liquid line refrigerant line fitting from the evaporator inlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings.
5. Disconnect the accumulator inlet tube refrigerant line fitting from the evaporator outlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings.
6. Drain the engine cooling system. Refer to Engine, Cooling and Exhaust/Cooling System/Service and Repair. Service and Repair
7. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes.
8. Unplug the heater-A/C system vacuum supply line connector from the tee fitting near the heater core tubes.

Fig.5 Heater-A/C Housing Remove/Install:

9. Remove the five nuts from the heater-A/C housing mounting studs on the engine compartment side of the dash panel. If necessary, loosen the battery hold-downs and reposition the battery for additional access.
10. Remove the cowl plenum drain tube from the heater-A/C housing mounting stud on the dash panel directly behind the engine cylinder head.
11. Remove the floor duct from the bottom of the heater-A/C housing. Refer to Heating and Air Conditioning/Air Duct/Service and Repair. Service and Repair
12. Remove the one screw that secures the heater-A/C housing to the plenum bracket on the passenger compartment side of the dash panel.
13. Pull the heater-A/C housing down far enough to clear the defrost/demist and fresh air ducts, and rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes.
14. Remove the heater-A/C housing from the vehicle.

INSTALLATION

WARNING: 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 AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Position the heater-A/C housing to the dash panel. Be certain that the evaporator condensate drain tube and the housing mounting studs are inserted into their correct mounting holes, and that the openings on the top of the housing are properly aligned with the fresh air duct and defrost/demist duct.
2. Install and tighten the one screw that secures the heater-A/C housing to the plenum bracket on the passenger compartment side of the dash panel. Tighten the screw to 3.4 Nm (30 in. lbs.).
3. Install the floor duct to the bottom of the heater-A/C housing. Refer to Heating and Air Conditioning/Air Duct/Service and Repair. Service and Repair
4. Install the cowl drain tube onto the heater-A/C housing mounting stud on the dash panel directly behind the engine cylinder head.
5. Install and tighten the five nuts onto the heater-A/C housing mounting studs on the engine compartment side of the dash panel. Tighten the nuts to 6.2 Nm (55 in. lbs.).
6. If the battery was repositioned during the removal procedure, position the battery and tighten the hold-downs.
7. Connect the heater-A/C system vacuum supply line connector to the tee fitting near the heater core tubes.
8. Unplug or remove the tape from the heater core tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system. Refer to Engine, Cooling and Exhaust/Cooling System/Service and Repair. Service and Repair
9. If the vehicle is not equipped with air conditioning, go to Step 13. If the vehicle is equipped with air conditioning, unplug or remove the tape from the accumulator inlet tube and the evaporator outlet tube fittings. Connect the accumulator inlet tube coupler to the evaporator outlet tube. Refer to Heating and Air Conditioning/Service and Repair. Service and Repair
10. Unplug or remove the tape from the liquid line and the evaporator inlet tube fittings. Connect the liquid line coupler to the evaporator inlet tube.
11. Evacuate the refrigerant system. Refer to Heating and Air Conditioning/Service and Repair. Service and Repair
12. Charge the refrigerant system. Refer to Heating and Air Conditioning/Service and Repair. Service and Repair
13. Install the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

14. Connect the battery negative cable.
15. Start the engine and check for proper operation of the heating and air conditioning systems.