Front HVAC Housing Removal and Installation

WARNING:
- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION.
- 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.

REMOVAL
1. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Procedures, Refrigerant - Recovery, Refrigerant - Recovery
2. Drain the engine cooling system.
3. Disconnect and isolate the negative battery cable.
4. Remove the windshield wiper module from the vehicle. Refer to: Wiper and Washer System, Wiper Motor, Service and Repair, Procedures, Front Wiper Motor Replacement, Front Wiper Motor Replacement
5. Disconnect the liquid line and suction line from the expansion valve.
6. Disconnect the heater hoses from the heater core tubes.

HVAC Housing Retainers - LHD Shown, RHD Typical:

7. On LHD models, remove the one bolt that secures the HVAC housing to the dash panel.
8. Remove the three nuts that secure the HVAC housing to the dash panel.
9. Remove the instrument panel from the passenger compartment Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, Instrument Panel Assembly
10. Remove the floor distribution duct. Refer to: Heating and Air Conditioning, Air Duct, Service and Repair, Procedures, Floor Distribution Ducts Replacement, Floor Distribution Ducts Replacement

HVAC Housing - LHD Models:

HVAC Housing - RHD Models:

11. Remove the bolt or bolts (depending on application) that secure the HVAC housing to the passenger compartment side of the dash panel.
12. Pull the HVAC housing rearward far enough for the mounting studs to clear the dash panel and remove the housing from the passenger compartment.

INSTALLATION
1. Position the HVAC housing into the passenger compartment with the mounting studs located in their proper mounting holes in the dash panel.
2. Install the bolt or bolts (depending on application) that secure the HVAC housing to the passenger compartment side of the dash panel. Tighten the bolt(s) to 3 Nm (26 in. lbs.).
3. Install the three nuts that secure the HVAC housing to the engine compartment side of the dash panel. Tighten the nuts to 7 Nm (62 in. lbs.).
4. On LHD models, install the one bolt that secures the HVAC housing to the engine compartment side of the dash panel. Tighten the bolt to 4 Nm (35 in. lbs.).
5. Reinstall the floor distribution duct. Refer to: Heating and Air Conditioning, Air Duct, Service and Repair, Procedures, Floor Distribution Ducts Replacement, Floor Distribution Ducts Replacement
6. Install the instrument panel.Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, Instrument Panel Assembly

7. Reconnect the heater hoses to the heater core tubes. Refer to: Heating and Air Conditioning, Air Duct, Service and Repair, Procedures, Floor Distribution Ducts Replacement, Floor Distribution Ducts Replacement
8. Reconnect the suction line and liquid line to the expansion valve.
9. Install the windshield wiper module. Refer to: Wiper and Washer System, Wiper Motor, Service and Repair, Procedures, Front Wiper Motor Replacement, Front Wiper Motor Replacement
10. Reconnect the negative battery cable.
11. Refill the engine cooling system.
12. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Procedures, Refrigerant - Evacuate, Refrigerant - Evacuate
13. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Procedures, Refrigerant - Charge Refrigerant - Charge.