HOUSING-AIR DISTRIBUTION

WARNING: 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury.

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation.  Failure to follow the warnings and cautions may result in possible serious or fatal injury.

NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors.

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

Fig. 91: Heater Core Removal/Installation

1. Remove the HVAC housing assembly and place it on a workbench.

2. Remove the floor distribution ducts from the HVAC housing assembly.

NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.

3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (5).

4. Remove the screw (6) that secures the flange to the HVAC housing and remove the flange.

5. On RHD models, remove the air distribution housing (3) from the HVAC housing.

6. Carefully pull the heater core (4) out of the air distribution housing.

Fig. 92: Air Distribution Housing-Removal/Installation

7. Remove the two metal retaining clips (3) that secure the bottom of air distribution housing (2) to the HVAC housing (4).

8. Remove the seven screws (1) that secure the air distribution housing to the rear of the HVAC housing.

9. Remove the air distribution housing from the rear of the HVAC housing.

10. If required, disassemble the air distribution housing.

HOUSING-AIR INLET

WARNING: 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury.

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in possible serious or fatal injury.

NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door.

NOTE: LHD model shown. RHD model similar.

Fig. 93: Air Inlet Housing-Removal/Installation

1. Remove the HVAC housing assembly and place it on a workbench.

2. If equipped, remove the particulate air filter.

3. Remove the four screws (1) that secure the air inlet housing (2) to the top of the HVAC housing (3).

4. Disengage the two plastic retaining tabs (4) that secure the air inlet housing to the HVAC housing and remove the inlet housing from the HVAC housing.

5. If required, disassemble the air inlet housing.

SCREEN-AIR INLET

NOTE: LHD model shown. RHD model similar.

Fig. 94: Screen-HVAC Housing Air Inlet

1. Remove the cowl grille screen.

2. Disengage the three push-in retainers (1) that secure the HVAC housing air inlet screen (2) to the cowl panel (3) and remove the screen.

HOUSING-HVAC

WARNING: 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury.

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in possible serious or fatal injury.

NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, air intake housing and the mode-air and blend-air doors.

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

Fig. 95: Heat Shield - Unified Line

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system.

3. Partially drain the engine cooling system.

4. If equipped with heat shield (3), remove the top nut (2) that secures the heat shield to the stud (1) located on the dash panel.

NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal, if equipped. Complete removal of the two bottom heat shield retaining nuts is not required.

5. If equipped, reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required.

Fig. 96: Unified Liquid & Suction Line to Evaporator

6. Remove the nut (1) that secures the A/C liquid and suction line assembly (2) to the A/C expansion valve (3).

7. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals.

8. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports.

9. Disconnect the heater hoses (4) from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal.

Fig. 97: HVAC Housing to Dash Panel Nut

NOTE: Make sure to remove the five bolts that secure the HVAC housing to the instrument panel support prior to removing the instrument panel from the vehicle.

10. Remove the instrument panel.

11. Remove the rear floor ducts.

12. Remove the condensation drain tube.

13. Remove the nut (1) that secures the passenger side of the HVAC housing (2) to the dash panel (3).

NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores.

14. Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger compartment.

Fig. 98: Air Inlet Duct

15. If required, remove the HVAC housing air inlet duct (2) from the passenger compartment side of the dash panel (1).