Front

HOUSING-HVAC ASSEMBLY

DISASSEMBLY

NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.




1. Remove the HVAC housing assembly and place it on a workbench.
2. Remove the air distribution housing (3) from the HVAC housing (1).
3. Remove the air inlet housing (2) from the HVAC housing.




4. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) and the blower motor resistor or power module (4) (depending on application).
5. Disconnect the wire harness for the blower motor (3) from the blower motor resistor or power module (depending on application).
6. Disengage the two HVAC wire harness retainers from the HVAC housing (5) and remove the wire harness.
7. Remove the blower motor.
8. Remove the blower motor resistor or power module, depending on application.
9. Remove the evaporator temperature sensor.




10. Remove the two bolts (1) that secure the A/C expansion valve (2) to the evaporator tube tapping block (3) located at the front of the HVAC housing (4).
11. Remove the A/C expansion valve from the evaporator tube tapping block and remove and discard the O-ring seals.
12. Install plugs in, or tape over the opened evaporator tube fittings and all expansion valve ports.




13. Carefully cut the foam seal (1) along the parting line (2) of the upper half of the HVAC housing (3) and the lower half of the HVAC housing (4). If the seal is deformed or damaged, it must be replaced.
14. Remove the three metal retaining clips (5) that secure the two halves of the HVAC housing together.
15. Remove the ten screws (6) that secure the two halves of the HVAC housing together.
16. Disengage the two plastic retaining clips (7) and separate the two halves of the HVAC housing.




17. Open the rubber seal (1) and carefully lift the A/C evaporator (2) and insulator (3) out of the lower half of the HVAC housing (4).
18. If required, remove the rubber seal from the lower half of the HVAC housing. If the seal is deformed or damaged, it must be replaced.
19. If required, remove the insulator from the A/C evaporator. If the insulator is deformed or damaged, it must be replaced.

ASSEMBLY




1. If removed, install the insulator (3) over the A/C evaporator (2). If the seal is deformed or damaged, it must be replaced.
2. If removed, install the rubber seal (1) into the lower half of the HVAC housing (4). If the seal is deformed or damaged, it must be replaced.
3. Install the A/C evaporator into the lower half of the HVAC housing. Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and that the insulator and rubber seal are properly installed.




4. Install the upper half of the HVAC housing (3) onto the lower half of the HVAC housing (4) and fully engage the two plastic retaining clips (7).
5. Install the ten screws (6) that secure the two halves of the HVAC housing together. Tighten the screws to 2.2 N.m (20 in lbs.).
6. Install the three metal retaining clips (5) that secure the two halves of the HVAC housing together.




7. Remove the tape or plugs from the evaporator tube fittings and all of the expansion valve ports.
8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator tube fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
9. Install the A/C expansion valve (2) onto the evaporator tube tapping block (3) located at the front of the HVAC housing (4).
10. Install the two bolts (1) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 N.m (97 in. lbs.).




11. Install the evaporator temperature sensor (2).
12. Install the blower motor resistor or power module (4), depending on application.
13. Install the blower motor (3).
14. Install the HVAC wiring harness (1) onto the HVAC housing (5) and engage the two wire harness retainers to the housing.
15. Connect the HVAC wire harness to the evaporator temperature sensor and blower motor resistor or power module (depending on application).
16. Connect the blower motor wire harness to blower motor resistor or power module (depending on application).




17. Install the air inlet housing (2) onto the HVAC housing (1).
18. Install the air distribution housing (3) onto the HVAC housing.
19. Install the HVAC housing assembly.