INSTALLATION
HOUSING-AIR DISTRIBUTION
NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.
NOTE: LHD model shown in illustrations. RHD model similar.
1. Position the air distribution housing (2) onto the rear of the HVAC housing (3) by inserting the tabs on the bottom of the distribution housing into the slots located on the bottom of the HVAC housing.
2. Tip the air distribution housing upward until it is properly aligned with the HVAC housing and the locking tabs at the top of the distribution housing are fully engaged.
3. Install the seven screws (1) that secure the air distribution housing to the HVAC housing. Tighten the screws to 2.2 N·m (20 in. lbs.).
4. Remove the tape or plugs from the heater core tubes (4) and the heater core (6).
5. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tube fittings. Use only the specified O-rings as they are made of a special material for the engine cooling system.
6. Install the heater core tubes onto the heater core and loosely install the bolt (5) that secures the tubes to the heater core.
7. Install the screw (1) that secures the heater core tube retaining bracket (2) to the HVAC housing (3). Tighten the screw to 2.2 N·m (20 in. lbs.).
8. Tighten the bolt that secures the heater core tubes to the heater core to 3 N·m (27 in. lbs.).
9. Install the heater core and tube cover (2) onto the HVAC housing (3).
10. Install the five screws (1) that secure the heater core and tube cover to the HVAC housing. Tighten the screws to 2.2 N·m (20 in. lbs.).
11. Connect the HVAC wire harness (1) to the mode door actuator (2) located near the bottom of the air distribution housing (3).
12. If equipped with dual zone heating-A/C, connect the HVAC wire harness to the blend door actuator (4) located on the passenger side of the air distribution housing.
13. Connect the HVAC wire harness (3) to the blend door actuator (4) and the mode door actuator (5) located on the driver side of the air distribution housing (2).
14. Engage the HVAC wire harness retainer (1) to the rear of the air distribution housing.
15. Install the HVAC housing assembly (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HVAC HOUSING ASSEMBLY - INSTALLATION).
HOUSING-AIR INLET
NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door.
NOTE: LHD model shown in illustration. RHD model similar.
1. Position the air distribution housing (4) onto the top of the HVAC housing (5) by inserting the two tabs located at the front of the air inlet housing into the slots located on the top of the HVAC housing.
2. Tip the air distribution housing downward until it is properly seated on the HVAC housing.
3. Install the three screws (3) that secure the air distribution housing to the HVAC housing. Tighten the screws to 2.2 N·m (20 in. lbs.).
4. Connect the HVAC wire harness (1) to the recirculation door actuator (2).
5. Install the HVAC housing assembly (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HVAC HOUSING ASSEMBLY - INSTALLATION).
HOUSING-HVAC ASSEMBLY
NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator.
NOTE: LHD model shown in illustrations. RHD model similar.
1. Position the HVAC housing assembly (2) into the passenger compartment side of the dash panel (3). Make sure that the condensate drain tube protrudes through the opening in the floor panel.
2. Loosely install the nut (1) that secures the HVAC housing to the passenger compartment side of the dash panel.
3. Install the two bolts (1) that secure the HVAC housing assembly (2) to the engine compartment side of the dash panel (3). Tighten the bolts to 7 N·m (62 in. lbs.).
4. Connect the heater hoses to the heater core tubes.
5. Connect the A/C suction line and A/C liquid line to the A/C evaporator (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING /LINE-A/C LIQUID - INSTALLATION).
6. Tighten the nut (1) that secures the HVAC housing assembly (2) to the passenger compartment side of the dash panel (3) to 7 N·m (62 in. lbs.).
7. Connect the right front floor duct (5) and left front floor duct (6) to the air distribution housing (4).
8. Connect the rear floor distribution duct (3) to the air distribution housing.
9. Connect the left rear floor duct (1) and the right rear floor duct (2) to the rear floor distribution duct.
10. Position the gear selector (3) to its installed location on the floor panel (6) and securely install the retaining screws (5).
11. Connect the front console duct (2) to the air distribution housing (4) and engage the push-pin retainer (1) to the gear selector.
12. Install the instrument panel (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION).
13. Install the floor console (Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE - INSTALLATION).
14. Reconnect the negative battery cable.
15. If the heater core is being replaced, flush the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING).
16. Refill the engine cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL).
17. Evacuate the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
18. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).