REMOVAL
HOUSING-AIR DISTRIBUTION
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.
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.
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. Remove the HVAC housing assembly and place it on a workbench (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HVAC HOUSING ASSEMBLY - REMOVAL).
2. Disengage the HVAC wire harness retainer (1) from the rear of the air distribution housing (2).
3. Disconnect the HVAC wire harness (3) from the blend door actuator (4) and the mode door actuator (5) located on the driver side of the air distribution housing.
4. Disconnect the HVAC wire harness (1) from the mode door actuator (2) located near the bottom of the air distribution housing (3).
5. If equipped with dual zone heating-A/C, disconnect the HVAC wire harness from the blend door actuator (4) located on the passenger side of the air distribution housing.
6. Remove the five screws (1) that secure the heater core and tube cover (2) to the HVAC housing (3).
7. Remove the heater core and tube cover from the HVAC housing.
NOTE: Take proper precautions to protect the carpeting from spilled engine coolant. Have absorbent toweling readily available to clean up any spills.
8. Remove the screw (1) that secures the heater core tube retaining bracket (2) to the HVAC housing (3).
9. Remove the bolt (5) that secures the heater core tubes (4) to the heater core (6).
10. Disconnect the heater core tubes from the heater core and remove and discard the O-ring seals.
11. Install plugs in, or tape over the opened heater core tubes and heater core ports.
12. Remove the seven screws (1) that secure the air distribution housing (2) to the HVAC housing (3).
13. Release the locking tabs located at the top of the distribution housing and tilt the distribution housing downward to disengage the tab-and-slot type retainers located at the bottom of the housing.
14. Remove the air distribution housing from the HVAC housing.
15. If required, disassemble the air distribution housing (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - AIR DISTRIBUTION HOUSING - DISASSEMBLY).
HOUSING-AIR INLET
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.
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.
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. Remove the HVAC housing assembly (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HVAC HOUSING ASSEMBLY - REMOVAL).
2. Disconnect the HVAC wire harness (1) from the recirculation door actuator (2).
3. Remove the three screws (3) that secure the air inlet housing (4) to HVAC housing (5).
4. Tilt the rear of the air inlet housing upward to disengage the two tab-and-slot type retainers located at the front of the inlet housing and remove the inlet housing from the HVAC housing.
NOTE: If the foam seal on the air inlet housing is deformed or damaged, it must be replaced.
5. If required, disassemble the air inlet housing (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - AIR INLET HOUSING - DISASSEMBLY).
HOUSING-HVAC ASSEMBLY
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.
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.
NOTE: The HVAC housing assembly must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator.
NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure.
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. Drain the engine cooling system (refer to 7 - COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN).
4. Remove the front floor console (refer to 23 - BODY/INTERIOR/FLOOR CONSOLE - REMOVAL).
5. Remove the instrument panel (refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL).
6. Disengage the push-pin retainer (1) that secures the front console duct (2) to the gear selector (3).
7. Disconnect the front console duct from the air distribution housing (4) and remove the console duct.
8. Remove the screws (5) that secure the gear selector to the floor panel (6) and position the gear selector out of the way.
9. Disconnect the left rear floor duct (1) and the right rear floor duct (2) from the rear floor distribution duct (3).
10. Disconnect the rear floor distribution duct from the air distribution housing (4) and remove the distribution duct.
11. Disconnect the right front floor duct (5) and the left front floor duct (6) from the air distribution housing and remove the floor ducts.
12. Remove the nut (1) that secures the HVAC housing assembly (2) to the passenger side of the dash panel (3).
13. Disconnect the A/C liquid line and the A/C suction line from the A/C evaporator (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/LINE-A/C LIQUID - REMOVAL).
14. Disconnect the heater hoses from the heater core tubes.
15. Remove the two bolts (1) that secure the HVAC housing assembly (2) to the engine compartment side of the dash panel (3).
16. Lift the HVAC housing assembly upwards so that the condensate drain tube clears the floor panel and remove the HVAC housing assembly from the passenger compartment.
17. If required, disassemble the HVAC housing assembly (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC ASSEMBLY - DISASSEMBLY).