REMOVAL
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 battery negative (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 an accidental airbag deployment and possible personal injury or death.
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION). Failure to follow the warnings and cautions could result in possible personal injury or death.
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.
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY).
3. Partially drain the engine cooling system (refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE - DRAINING COOLING SYSTEM).
4. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield.
5. Remove the bolt (1) that secures the A/C liquid and suction line assembly (2) to the A/C evaporator (3).
6. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals.
7. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports.
8. 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.
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.
9. Remove the instrument panel (refer to 23 - BODY/INSTRUMENT PANEL/ASSEMBLY-INSTRUMENT PANEL - REMOVAL).
10. Remove the rear floor ducts (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DUCTS-FLOOR DISTRIBUTION - REMOVAL).
11. Remove the condensation drain tube (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/TUBE-CONDENSATION DRAIN - REMOVAL).
12. 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.
13. Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger compartment.
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 take the proper precautions could result in accidental airbag deployment and possible personal injury or death.
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION). Failure to follow the warnings and cautions could result in possible personal injury or death.
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 with A/C shown in illustrations. RHD and heater-only models similar.
1. Remove the HVAC housing assembly and place it on a workbench (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION /HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - REMOVAL).
2. Remove all of the floor distribution ducts from the air distribution housing (5) (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DUCTS-FLOOR DISTRIBUTION - REMOVAL).
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 (9).
4. Remove the screw (10) that secures the flange to the front of the HVAC housing and remove the flange.
5. Remove the screw (3) that secures the retaining bracket (4) for the heater core tubes (8) to the left side of the air distribution housing.
6. On RHD models, remove the air distribution housing from the HVAC housing (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR DISTRIBUTION - REMOVAL)
7. Carefully pull the heater core (6) out of the driver side of the air distribution housing.
NOTE: Illustration shown with heater core and tubes removed from view for clarity.
8. Remove the two metal retaining clips (3) that secure the bottom of air distribution housing (2) to the HVAC housing (4).
9. Remove the seven screws (1) that secure the air distribution housing to the rear of the HVAC housing.
10. Remove the air distribution housing from the rear of the HVAC housing.
11. If required, disassemble the air distribution housing (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR DISTRIBUTION - DISASSEMBLY).
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 take the proper precautions could result in accidental airbag deployment and possible personal injury or death.
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION). Failure to follow the warnings and cautions could result in possible personal injury or death.
NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door.
NOTE: LHD model with A/C shown. RHD and heater-only models similar.
1. Remove the HVAC housing assembly and place it on a workbench (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - REMOVAL).
2. If equipped, remove the particulate air filter (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/FILTER-PARTICULATE AIR - REMOVAL).
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 (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR INLET - DISASSEMBLY).
SCREEN-AIR INLET
NOTE: LHD model shown. RHD model similar.
1. Remove the cowl grille screen (refer to 23 - BODY/EXTERIOR/SCREEN-COWL GRILLE - REMOVAL).
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.