INSTALLATION
AIR INLET HOUSING
NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door.
1. Position the air inlet housing (3) onto the top of the HVAC housing (7).
2. Install the four screws (4) that secure the air inlet housing to the top of the HVAC housing. Tighten the screws to 2 N·m (17 in. lbs.).
3. If removed, install the recirculation door actuator (5) onto the HVAC housing (refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/ACTUATOR-RECIRCULATION DOOR - INSTALLATION).
4. Connect the recirculation door actuator to the recirculation door lever (2).
5. If removed, install the HVAC vacuum harness (1) into the routing retainers located on the HVAC housing.
6. Connect the HVAC vacuum harness connector (6) to the recirculation door actuator.
NOTE: If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced.
7. Install the HVAC housing (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - INSTALLATION).
8. Reconnect the negative battery cable.
HVAC HOUSING
NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator and the mode-air and blend-air doors.
NOTE: LHD model shown in illustrations. RHD model similar.
NOTE: Make sure that no foreign material or debris is blocking or restricting the air flow through the air inlet screen at the top of the dash panel. Use a vacuum to remove any foreign material or debris as necessary.
1. If removed, install the fresh air inlet screen (5) onto the top of the dash panel (1) (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - SCREEN-AIR INLET - INSTALLATION).
2. Position the HVAC housing to the dash panel (4). Be certain that the condensate drain and the housing mounting studs are inserted into their correct locations.
3. Loosely install the two nuts (3) that secure the HVAC housing to the passenger compartment side of the dash panel.
4. Install the one nut (2) that secures the HVAC housing to the engine compartment side of the dash panel. Tighten the nut to 6 N·m (53 in. lbs.).
5. Install the condensation drain tube (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/TUBE-CONDENSATION DRAIN - INSTALLATION).
6. Connect the HVAC system vacuum supply line to the engine vacuum harness at the connector located near the evaporator tapping block.
7. Remove the previously installed plugs or caps and connect the heater hoses to the heater core tubes.
8. Remove the previously installed plugs or caps from the opened refrigerant line filltings and evaporator ports.
9. Connect the refrigeant lines to the A/C evaporator using new O-ring seals and install the two nuts that secure the A/C accumulator to the dash panel (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING /LINE-A/C LIQUID - INSTALLATION) and (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ACCUMULATOR-A/C - INSTALLATION).
10. Tighten the two nuts that secure the HVAC housing to the passenger compartment side of the dash panel to 6 N·m (53 in. lbs.).
11. Position the dash panel wire harness (2) to the top of the HVAC air inlet housing (3) and engage the three retaining straps (1) that secure the wire harness to the housing.
12. Install the instrument panel (refer to 23 - BODY/INSTRUMENT PANEL ASSEMBLY - INSTALLATION).
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 - STANDARD PROCEDURE - COOLING SYSTEM REFILL).
16. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
17. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
FRESH AIR INLET SCREEN
CAUTION: Replacement of the fresh air inlet screen is required once the screen is removed from the dash panel. Failure to follow this caution can result in a water leak within the vehicle and possible damage to the blower motor and resistor.
NOTE: LHD model shown. RHD model similar.
1. Position a new fresh air inlet screen to the top of the dash panel (3) and engage the two retaining tabs (4).
2. Install the two nuts (1) that secure the fresh air inlet screen to the dash panel. Tighten the nuts to 6 N·m (53 in. lbs.).
NOTE: Make sure that no foreign material or debris is present on the top of the dash panel in the engine compartment which could possibly block or restrict air flow through the fresh air inlet screen or cause rustling type noises when the blower motor is operated. Use a vacuum to remove any foreign material or debris as necessary.
3. Install the cowl grille (refer to 23 - BODY/EXTERIOR/GRILLE-COWL - INSTALLATION).
4. Install the wiper arms (refer to 8 - ELECTRICAL/WIPERS/WASHERS/ARMS-WIPER - INSTALLATION).