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 or death.

NOTE: The HVAC housing must be removed from the vehicle and the two halves of the housing separated for service of the heater core, A/C evaporator, blend door and each of the various mode doors.

1. Disconnect and isolate the negative battery cable.
2. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, Dashboard / Instrument Panel

3. If the vehicle is not equipped with A/C, go to Step 8. If the vehicle is equipped with A/C, recover the refrigerant from the refrigerant system. Refer to Heating and Air Conditioning, Refrigerant, Service and Repair. Service and Repair

4. Remove the accumulator and mounting bracket from the dash panel.

HVAC Housing:

5. Remove the nuts that secure the suction and liquid lines to the evaporator tapping block.
6. Disconnect the suction and liquid lines from the evaporator tapping block and remove and discard the O-ring seals.
7. Install plugs in, or tape over the opened suction and liquid line fittings and evaporator tapping block ports.
8. Drain the engine cooling system. Refer to Engine, Cooling and Exhaust, Cooling System, Service and Repair. Service and Repair

9. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes.
10. Disconnect the HVAC system vacuum supply line connector from the engine vacuum harness.
11. Remove the nuts that secure the HVAC housing to the dash panel in the engine compartment.
12. Remove the HVAC housing from inside the vehicle taking care not to allow any remaining coolant to drain on the vehicles interior.

INSTALLATION

NOTE: Use only the specified O-rings as they are made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor in the vehicle.

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 the nuts that secure the HVAC housing to the dash panel in the engine compartment. Tighten the nuts to 6 N-m (53 in. lbs.).
3. Connect the HVAC system vacuum supply line connector.
4. Unplug or remove the tape from the heater core tubes and connect the heater hoses to the heater core tubes.
5. If the vehicle is not equipped with A/C, go to Step 13. If the vehicle is equipped with A/C, unplug or remove the tape from the liquid and suction line fittings and the evaporator tapping block.
6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the liquid and suction line fittings.
7. Connect the liquid and suction lines to the evaporator tapping block.
8. Install the nuts that secure the liquid and suction lines to the evaporator tapping block. Tighten the nuts to 23 N-m (17 ft. lbs.).
9. Install the accumulator and mounting bracket to the mounting studs on the dash panel. Tighten the nuts to 4.5 N-m (40 in. lbs.).
10. Install the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, Dashboard / Instrument Panel

11. Evacuate the refrigerant system. Refer to Heating and Air Conditioning, Refrigerant, Service and Repair. Service and Repair

12. Charge the refrigerant system. Refer to Heating and Air Conditioning, Refrigerant, Service and Repair. Service and Repair

13. Reconnect the negative battery cable.
14. If the heater core is being replaced, flush the cooling system. Refer to Engine, Cooling and Exhaust, Cooling System, Service and Repair. Service and Repair

15. Refill the engine cooling system. Refer to Engine, Cooling and Exhaust, Cooling System, Service and Repair. Service and Repair