Removal and Replacement

REMOVAL

WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

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

1. Disconnect and isolate the battery negative cable.
2. If the vehicle is not equipped with air conditioning, go to Step 5. If the vehicle is equipped with air conditioning, recover the refrigerant from the refrigerant system.
3. Disconnect the liquid refrigerant line fitting from the evaporator inlet tube. Discard the O-ring seal and install plugs in, or tape over the opened liquid refrigerant line fitting and evaporator inlet tube.
4. Disconnect the accumulator inlet fitting from the evaporator outlet tube. Discard the O-ring seal and install plugs in, or tape over the opened accumulator inlet fitting and evaporator outlet tube.
5. Drain the engine cooling system.
6. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes.
7. Unplug the HVAC system vacuum supply line connector from the tee fitting near the heater core tubes.
8. Remove the five nuts from the HVAC housing mounting studs in the engine compartment. If necessary, loosen the battery hold-downs and reposition the battery for additional access.
9. Remove the cowl plenum drain tube from the HVAC housing mounting stud on the dash panel directly behind the engine cylinder head.
10. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, Instrument Panel Assembly

11. Remove the floor distribution duct from the bottom of the HVAC housing.

HVAC Housing - LHD Shown, RHD Typical:

12. Remove the screw that secures the HVAC housing to the dash panel bracket located on the passenger side of vehicle.
13. Pull the HVAC housing down far enough to clear the defroster and fresh air ducts, and rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel.
14. Remove the HVAC housing from the vehicle.

INSTALLATION
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, and that the openings on the top of the housing are properly aligned with the defroster and fresh air ducts.
2. Install and tighten the screw that secures the HVAC housing to the dash panel bracket on the passenger side of the vehicle. Tighten the screw to 3.4 Nm (30 in. lbs.).
3. Install the floor distribution duct to the bottom of the HVAC housing.
4. Install the cowl drain tube onto the HVAC housing mounting stud on the dash panel directly behind the engine cylinder head.
5. Install and tighten the five nuts onto the HVAC housing mounting studs in the engine compartment. Tighten the nuts to 6.2 Nm (55 in. lbs.).
6. Install the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, Instrument Panel Assembly

7. If the battery was repositioned during the removal procedure, position the battery and tighten the hold-downs.
8. Connect the HVAC system vacuum supply line connector to the tee fitting near the heater core tubes.
9. Unplug or remove the tape from the heater core tubes and connect the heater hoses to the heater core tubes.
10. Fill the engine cooling system.
11. If the vehicle is not equipped with air conditioning, go to Step 15. If the vehicle is equipped with air conditioning, unplug or remove the tape from the accumulator inlet tube fitting and the evaporator outlet tube. Using a new O-ring seal, connect the accumulator inlet tube fitting to the evaporator outlet tube.
12. Unplug or remove the tape from the liquid line fitting and the evaporator inlet tube. Using a new O-ring seal, connect the liquid line to the evaporator inlet tube.
13. Evacuate the refrigerant system.
14. Charge the refrigerant system.
15. Reconnect the battery negative cable.
16. Start the engine and check for proper operation of the heating and air conditioning systems.