Heater-A/C Housing Removal and Installation

REMOVAL

WARNING: If equipped with air conditioning, the refrigeration system must be completely empty before proceeding.

1. Set parking brake.
2. Disconnect battery negative cable.

Valve Service Ports:

3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Refer to: "Testing and Inspection" Testing and Inspection
4. Remove the wiper arms.
5. Remove the cowl cover.
6. Release the hood latch and open hood.

Wiper Unit Wire Connector:

7. Disconnect the positive lock on the wiper unit wire connector.
8. Disconnect the wiper unit wire connector from the engine compartment wire harness.
9. Disconnect the windshield washer hose from coupling inside unit.
10. Disconnect the drain tubes from nipples on bottom of the wiper unit.
11. Remove nuts holding wiper unit to lower windshield fence.

Wiper Unit:

12. Remove bolts holding the wiper unit to the dash panel.
13. Lift wiper unit from weld-studs on lower windshield fence.

CAUTION: Do not allow wiper unit to rest on brake master cylinder reservoir, damage to brake system can result.

14. Remove wiper unit.
15. Pinch off rear heater lines if equipped.

Heater Hoses:

16. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" Service and Repair

A/C Refrigerant Plate:

17. Remove suction and liquid lines at the expansion valve.
18. Remove the lower console.

Heat Duct:

19. Remove the screw holding the lower heat duct to the instrument panel support.
20. Disconnect the heat duct from the vehicle.

Lower Supports:

21. Remove the bolts holding the lower supports to the instrument panel frame.
22. Remove the bolts holding the lower supports to the floor pan.
23. Remove the right and left end covers.
24. Disconnect the wire connectors from the Passenger Airbag Module.
25. Remove the front door sill trim covers. Refer to: "Body and Frame : Interior Trim : Trim Panel : Service and Repair" Service and Repair
26. Remove the A-pillar trim covers. Refer to: "Body and Frame : Interior Trim : Trim Panel : Service and Repair" Service and Repair
27. Remove the glove box.
28. Disconnect the antenna lead connector from behind the glove box.
29. Remove the lower steering column cover.
30. Remove the knee blocked panel.

Body Control Module Connectors:

31. Disconnect the lower two, forty pin wire harness connectors, from the main Junction Block near left cowl side panel.
32. Disconnect the instrument panel wire harness connector from the bottom of Body Control Module.

40 Way Connectors:

33. Disconnect the two forty pin connectors from the right of the steering column.
34. Remove the clinch bolt holding upper the steering shaft to the lower steering shaft.
35. Separate the upper steering shaft from the tower steering shaft.
36. Remove the nuts holding the instrument panel frame to the die-cast brake pedal support on each side of the steering column.
37. With mechanical transmission range indicator:
- Remove the indicator cable loop.
- Remove the clip holding gear shift cable end to the gear selector adaptor
- Pull the cable end from gear selector.
- Disconnect the clip for the indicator cable and guide tube from the shift cable bracket and move out of the way.
38. Remove the nut holding gear shift cable bracket to the instrument panel frame.
39. Remove the bracket from the instrument panel.
40. Remove the screw holding hood release handle to the instrument panel.
41. Remove the bolt holding the hood release handle to the instrument panel. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair".Service and Repair>
42. Position the hood release handle out of the way.
43. Remove the instrument panel top cover.
44. Disconnect the wire connector from the HVAC wire harness behind the glove box area.

Passenger Side Instrument Panel:

Drivers Side Instrument Panel:

45. Remove the bolts holding the instrument panel frame to the brackets on cowl side panels.
46. Loosen, but do not remove, the pivot bolts holding the instrument panel to the cowl panels.
47. Remove the bolts holding the instrument panel frame to the dash panel below windshield opening.
48. Remove the instrument panel from vehicle. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair".Service and Repair
49. Remove heater ducts.
50. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the tunnel.

HVAC Bolt-up:

51. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel.
52. Disconnect the HVAC housing wiring harness.
53. Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle.

INSTALLATION
1. For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing inlets.
2. Evacuate and recharge the A/C system.
3. Perform HVAC Control Calibration Diagnostic and Cool-down test. Refer to: "Testing and Inspection" Testing and Inspection