REMOVAL
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 the floor distribution ducts from the air distribution housing (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 (4) located on the front of the HVAC housing (2).
4. Remove the screw (3) that secures the flange to the HVAC housing and remove the flange.
5. Remove the screw (1) that secures the bracket (2) retaining the heater core tubes (3) to the passenger side of the air distribution housing (5) and remove the bracket.
6. Carefully pull the heater core (4) out of the side of the air distribution housing.
7. Remove the two metal retaining clips (3) that secure the bottom of air distribution housing (2) to the HVAC housing (4).
8. Remove the seven screws (1) that secure the air distribution housing to the rear of the HVAC housing.
9. Remove the air distribution housing from the HVAC housing.
10. 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 shown. RHD model 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 the four screws (2) that secure the air inlet housing (1) to the top of the HVAC housing (3) and remove the inlet housing from the HVAC housing.
NOTE: If the foam seal on the top of the inlet housing is deformed or damaged, the seal must be replaced.
3. 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 HVAC housing assembly (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - REMOVAL).
2. Disengage the retaining tabs that secure the air inlet screen (1) to the passenger compartment side of the cowl panel (2).
3. Pull the air inlet screen straight downward and remove the screen from the cowl panel.
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 and instrument panel must be removed from the vehicle as an assembly.
NOTE: The HVAC housing must be removed from the instrument panel and disassembled for service of the A/C evaporator, air intake housing, mode-air and blend-air doors and the heater core.
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 nut (2) that secures the A/C liquid line (3) and A/C suction line (5) to the A/C expansion valve (1).
5. Disconnect the A/C liquid and suction lines from the A/C expansion valve and remove and discard the O-ring seals.
6. Install plugs in, or tape over the opened refrigerant line fittings and the expansion valve ports.
7. If equipped with the 3.8L engine, remove the upper intake manifold to help gain access to the hose clamps that secure the heater hoses to the heater core (refer to 9 - ENGINE/MANIFOLDS/MANIFOLD-INTAKE-UPPER - REMOVAL).
8. Using cable-type spring clamp pliers or equivalent, release the hose clamps that secure the heater hoses (2) to the heater core tubes (1) and disconnect the hoses from the tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during HVAC housing assembly removal.
9. Remove the instrument panel and place it on a workbench (refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL).
10. Remove the instrument panel cover (refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL COVER - REMOVAL).
11. Disconnect the instrument panel wire harness connectors from the evaporator temperature sensor, blower motor resistor, blower motor and the recirculation door actuator.
12. Remove the two bolts (1) that secure the air inlet housing (4) to the passenger side of the instrument panel support (3). Use caution not to damage the housing alignment pin (2) during removal of the HVAC housing assembly from the support.
13. Remove the demister ducts (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DUCTS-INSTRUMENT PANEL DEMISTER - REMOVAL).
14. Remove the defroster duct (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DUCT-DEFROSTER - REMOVAL).
15. Remove the instrument panel ducts (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DUCTS-INSTRUMENT PANEL - REMOVAL).
16. Remove the four bolts (1) that secure the HVAC housing assembly (3) to the center of the instrument panel support (2) and remove the housing from the support. Use caution not to damage the housing alignment pin (4) during removal of the housing from the support.