HOUSING-HVAC

NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.

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 air inlet housing (2) from the HVAC housing (1) (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR INLET - REMOVAL).
3. Remove the air distribution housing (3) from the HVAC housing (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR DISTRIBUTION - REMOVAL).


4. Remove the three screws (1) that secure the blower motor (2) to the bottom of the HVAC housing (3) and remove the blower motor.
5. Remove the two screws (4) that secure the blower motor resistor (5) to the back of the HVAC housing and remove the resistor.


6. Using needle nose pliers (1) , disengage the two retaining tabs (2) that secure the evaporator temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor.


7. Remove the A/C expansion valve from the A/C evaporator (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/VALVE-A/C EXPANSION - REMOVAL).

NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.


8. Remove the foam seal (2) from the flange (3) located on the top of the HVAC housing (4).
9. Remove the four screws (1) that secure the flange to the HVAC housing and remove the flange.

NOTE: If the foam insulator for the evaporator is deformed or damaged, it must be replaced.


10. Carefully remove the A/C evaporator (1) and its insulator (2) from the HVAC housing (3).

NOTE: If the foam seal for the condensate drain is deformed or damaged, it must be replaced.


11. If required, remove the foam seal (1) from around the condensate drain located on the bottom of the HVAC housing (2).


12. Remove the two metal clips (1) and ten screws (2) that secure the two halves of the HVAC housing together (4 and 5).
13. Disengage the eight plastic retaining tabs (4) that secure the two halves of the HVAC housing together and separate the housing.