Front HVAC Housing Removal and Installation

REMOVAL
The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the heater core, evaporator coil, blend-air module, various doors and linkages.

WARNING:
- REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION NEAR THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION.
- 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. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN 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 Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, Refrigerant System Recovery

4. Remove the front expansion valve from the evaporator tube mounting flange. Install plugs in, or tape over all of the opened refrigerant line fittings. Refer to: "Heating and Air Conditioning: Expansion Valve" Service and Repair

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. Remove the four nuts from the heater-A/C housing mounting studs on the engine compartment side of the dash panel.
8. Disengage the front floor panel transmission tunnel duct from the adapter on the heater-A/C housing.
9. Remove the two screws that retain the hanger strap and air inlet to the plenum.
10. Pull the heater-A/C housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes.
11. Remove the heater-A/C housing from the vehicle.

INSTALLATION
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.
2. Install the screw that secures the heater-A/C housing inlet to the plenum on the passenger compartment side of the dash panel.
3. Install and tighten the four nuts onto the heater-A/C housing mounting studs on the engine compartment side of the dash panel. Tighten the nuts to 7 Nm (60 in. lbs.).
4. Install the screw that secures the hanger strap to the plenum.
5. Engage the front floor panel transmission tunnel duct with the adapter on the heater-A/C housing.
6. 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. Service and Repair

7. Reinstall the front expansion valve to the evaporator tube mounting flange. Refer to: "Heating and Air Conditioning: Expansion Valve" Service and Repair

8. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Refrigerant System Evacuate

9. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Capacity, Refrigerant System Capacity

10. Reinstall 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

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