HVAC Housing - Removal and Installation

HOUSING-HVAC ASSEMBLY

NOTE:
- The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.
- LHD model shown in illustrations. RHD model similar.

REMOVAL

WARNING:
- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.
- 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 NEGATIVE BATTERY (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 AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. Air Bag(s) Arming and Disarming




1. Recover the refrigerant from the refrigerant system.
2. Drain the engine cooling system. Service and Repair
3. Disconnect and isolate the negative battery cable. Service and Repair
4. Remove the fresh air inlet housing from the dash panel.
5. Disconnect the A/C liquid line and the A/C suction line from the A/C evaporator.
6. Disconnect the heater hoses from the heater core tubes.
7. Remove the three nuts (1 and 3) that secure the HVAC housing to the engine compartment side of the dash panel (2).
8. Remove the instrument panel from the passenger compartment. Service and Repair




9. Disconnect the floor console duct. Service and Repair
10. Disconnect the rear floor distribution ducts.
11. Remove the defroster ducts.
12. Remove the two nuts (1) that secure the HVAC housing (2) to the passenger compartment side of the dash panel (5).
13. Pull the HVAC housing assembly rearward so that the mounting studs clear the dash panel.
14. Lift the HVAC housing assembly upwards so that the condensate drain tube clears the grommet (4) in the floor panel (3) and remove the HVAC housing assembly from the passenger compartment.
15. If required, disassemble the HVAC housing assembly.

INSTALLATION




1. Position the HVAC housing (2) into the passenger compartment with the mounting studs in their proper locations in the dash panel (5) and the condensate drain tube into the grommet (4) on the floor panel (3).
2. Install the two nuts (1) that secure the HVAC housing to the passenger compartment side of the dash panel. Tighten the nuts to 3 N.m (26 in. lbs.).
3. Install the defroster ducts.
4. Connect the floor distribution ducts.
5. Connect the floor console duct.
6. Install the instrument panel.




7. Install the three nuts (1 and 3) that secure the HVAC housing to the engine compartment side of the dash panel (2). Tighten the nuts to 7 N.m (62 in. lbs.).
8. Connect the heater hoses to the heater core tubes.
9. Connect the A/C suction line and A/C liquid line to the A/C evaporator.
10. Install the fresh air inlet housing to the engine compartment side of the dash panel.
11. Reconnect the negative battery cable.
12. If the heater core is being replaced, flush the cooling system. Service and Repair
13. Refill the engine cooling system.
14. Evacuate the refrigerant system.
15. Charge the refrigerant system.