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HVAC Housing







HOUSING-HVAC

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemRefrigerant Oil Capacity .

NOTE: If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

NOTE: LHD model shown in illustrations. RHD model similar.





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





3. Install the upper half of the HVAC housing (3) onto the lower half of the HVAC housing (4).
4. Install the screws (2) that secure the two halves of the HVAC housing together. Tighten the screws to 2.2 Nm (20 in lbs.).
5. Install the HVAC wiring harness (1). Make sure the harness is routed through all wiring retainers.





6. Remove the tape or plugs from the evaporator tube fittings and all of the expansion valve ports.
7. 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.
8. Install the A/C expansion valve (2) onto the evaporator tube tapping block located within the foam seal (3).
9. Install the two bolts (1) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 Nm (97 in. lbs.).





10. Install the evaporator temperature sensor (2) Evaporator Temperature Sensor - Installation.
11. Install the blower motor resistor or power module (3), depending on application Installation or Blower Motor Power Module - Installation.
12. Install the blower motor (4) Installation.
13. Connect the HVAC wire harness (1) to the evaporator temperature sensor, blower motor resistor or power module (depending on application) and the blower motor.
14. Install the two HVAC wire harness retainers (5) onto the blower motor.





15. Install the heater core tubes (4) and the flange (2) to the front of the HVAC housing (3).
16. Install the two screws (1) that secure the flange to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.).





17. Install the air inlet housing (2) onto the HVAC housing (1) HVAC Housing - Installation.
18. Install the air distribution housing (3) onto the HVAC housing HVAC Housing - Installation.
19. Install the HVAC housing assembly HVAC Housing - Installation.
20. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Capacity. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

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