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 AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

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 Assembly Replacement, Service and Repair

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/Procedures

Fig.5 HVAC Case Assembly:

4. Disconnect the liquid line refrigerant line fitting from the evaporator inlet tube. Refer to Hose/Line HVAC/Service and Repair/Procedures
5. Disconnect the accumulator inlet tube refrigerant line fitting from the evaporator outlet tube. Refer to Hose/Line HVAC/Service and Repair/Procedures . Install plugs in, or tape over all of the opened refrigerant line fittings.
6. Drain the engine cooling system.
7. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes.
8. Unplug the HVAC system vacuum supply line connector from the engine side harness.
9. Remove the nuts from the HVAC housing mounting studs.
10. Remove the HVAC housing from inside the vehicle taking care not to allow any remaining coolant to drain on the vehicles interior.

INSTALLATION

WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR CONDITIONING, REVIEW THE WARNINGS AND CAUTIONS IN PLUMBING BEFORE PERFORMING THE FOLLOWING OPERATION. Service Precautions

1. Position the HVAC 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.
2. Install and tighten the nuts onto the HVAC housing mounting studs. Tighten the nuts to 6.2 Nm (55 in.lbs.).
3. Connect the HVAC system vacuum supply line connector.
4. 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.
5. If the vehicle is not equipped with air conditioning, go to Step 10.
6. 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. Refer to Hose/Line HVAC/Service and Repair/Procedures.
7. Evacuate the refrigerant system. Refer to Heating and Air Conditioning/Service and Repair/Procedures.
8. Charge the refrigerant system. Refer to Heating and Air Conditioning/Service and Repair/Procedures
9. Install the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, Service and Repair

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