HOUSING-HVAC

NOTE: LHD model shown in illustrations. RHD model similar.




1. Position the HVAC housing assembly (3) into the instrument panel support (2). Be certain that the housing alignment pin (4) is correctly located.
2. Install the four bolts (1) that secure the HVAC housing assembly to the center of instrument panel support. Tighten the bolts to 4 Nm (35 in. lbs.).

NOTE: If a foam seal on the top of the HVAC housing is deformed or damaged, the seal must be replaced.


3. Install the instrument panel ducts (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DUCTS-INSTRUMENT PANEL - INSTALLATION).
4. Install the defroster duct (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DUCT-DEFROSTER - INSTALLATION).
5. Install the demister ducts (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DUCTS-INSTRUMENT PANEL DEMISTER - INSTALLATION).


6. Verify that the housing alignment pin (2) is correctly located in the passenger side of the instrument panel support (3).
7. Install the two bolts (1) that secure the air inlet housing (4) to the instrument panel support. Tighten the bolts to 4 Nm (35 in. lbs.).
8. Connect the instrument panel wire harness connectors to the evaporator temperature sensor, blower motor resistor, blower motor and the recirculation door actuator.
9. Install the instrument panel cover (refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL COVER - INSTALLATION).
10. Install the instrument panel (refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION).


11. Remove the previously installed plugs or caps and connect the heater hoses (2) to the heater core tubes (1).
12. Using cable-type spring clamp pliers or equivalent, correctly position the two hose clamps that secure the heater hoses to the heater core tubes and engage the clamps to the tubes.
13. If equipped with the 3.8L engine, install the upper intake manifold (refer to 9 - ENGINE/MANIFOLDS/MANIFOLD-INTAKE-UPPER - INSTALLATION).


14. Remove the tape or plugs from the opened refrigerant line fittings and the expansion valve ports.
15. Lubricate new O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
16. Connect the A/C liquid line (3) and A/C suction line (5) onto the A/C expansion valve (1).
17. Install the nut (2) that secures the A/C liquid and suction lines to the A/C expansion valve. Tighten the nut to 8 Nm (70 in. lbs.).
18. Reconnect the negative battery cable.
19. If the heater core is being replaced, flush the cooling system (refer to 7 - COOLING - STANDARD PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING).
20. Refill the engine cooling system (refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE - COOLING SYSTEM FILL).
21. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
22. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).