INSTALLATION
HOUSING-HVAC
NOTE: LHD model shown in illustrations. RHD model similar.
1. Position the HVAC housing assembly (2) to the dash panel (3). Be certain that the passenger side of the HVAC housing is correctly located over the dash panel mounting stud.
2. Install the nut (1) that secures the HVAC housing to the passenger compartment side of dash panel. Tighten the nut to 4.5 N·m (40 in. lbs.).
3. Install the condensation drain tube (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/TUBE-CONDENSATION DRAIN - INSTALLATION).
4. Install the rear floor ducts (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DUCTS-FLOOR DISTRIBUTION - INSTALLATION).
5. Install the instrument panel (refer to 23 - BODY/INSTRUMENT PANEL/ASSEMBLY-INSTRUMENT PANEL - INSTALLATION).
6. Remove the previously installed plugs or caps and connect the heater hoses (4) to the heater core tubes.
7. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
8. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
9. Connect the A/C liquid and suction line assembly (2) to the A/C evaporator (3).
10. Install the bolt (1) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 N·m (105 in. lbs.).
11. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.
12. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 N·m (10 in. lbs.).
13. Reconnect the negative battery cable.
14. If the heater core is being replaced, flush the cooling system (refer to 7 - COOLING - STANDARD PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING).
15. Refill the engine cooling system (refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE - COOLING SYSTEM FILL).
16. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
17. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
HOUSING-AIR DISTRIBUTION
NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.
NOTE: Illustration shown with heater core and tubes removed from view for clarity.
1. Position the air distribution housing (2) onto the rear of the HVAC housing (4).
2. Install the two metal retaining clips (3) that secure the bottom of the air distribution housing to the HVAC housing.
3. Install the seven screws (1) that secure the air distribution housing to the HVAC housing. Tighten the screws to 1.2 N·m (10 in. lbs.).
4. Carefully install the heater core (6) into the left side of the air distribution housing (5).
5. On RHD models, install the air distribution housing onto the HVAC housing (9) (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR DISTRIBUTION - INSTALLATION).
6. Install the retaining bracket (4) and screw (3) that secure the heater core tubes (8). Tighten the screw to 1.2 N·m (10 in. lbs.)
7. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing.
8. Install the screw (10) that secures the flange to the HVAC housing. Tighten the screw to 1.2 N·m (10 in. lbs.).
NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
9. Install the foam seal (1) onto the flange.
10. Install all of the floor distribution ducts onto the air distribution housing (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DUCTS-FLOOR DISTRIBUTION - INSTALLATION).
NOTE: If the heater core is being replaced, flush the cooling system (refer to 7 - COOLING - STANDARD PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING).
11. Install the HVAC housing assembly (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - INSTALLATION).
HOUSING-AIR INLET
NOTE: LHD model with A/C shown. RHD and heater-only models similar.
1. Install the air inlet housing (2) onto the top of the HVAC housing (3) and engage the two plastic retaining tabs (4). Make sure the retaining tabs are fully engaged.
2. Install the four screws (1) that secure the air inlet housing to the HVAC housing. Tighten the screws to 1.2 N·m (10 in. lbs.).
3. If equipped, install the particulate air filter (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/FILTER-PARTICULATE AIR - INSTALLATION).
4. Install the HVAC housing assembly (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - INSTALLATION).
SCREEN-AIR INLET
NOTE: LHD model shown. RHD model similar.
1. Position the HVAC housing air inlet screen (2) to the cowl panel (3) and fully engage the three push-in retainers (1) that secure the screen to the panel.
2. Install the cowl grille screen (refer to 23 - BODY/EXTERIOR/SCREEN-COWL GRILLE - INSTALLATION).