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Part 2 – HVAC sub assembly elimination and set up
The HVAC housing assembly have to be faraway from the car and the 2 halves of the housing separated for service entry of the heater core, evaporator coil, mix door(s), and every of the varied mode doorways.
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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.
1. Disconnect and isolate the battery damaging cable.
2. Remove the instrument panel from the car (see Part 1 – Instrument panel removal)
3. Recover the refrigerant from the refrigerant system.
4. Disconnect the liquid line refrigerant line from the evaporator inlet tube. Install plugs in, or tape over all the opened refrigerant line fittings.
5. Disconnect the suction line refrigerant line from the evaporator outlet tube. Install plugs in, or tape over all the opened refrigerant line fittings.
6. Disconnect the heater hoses from the heater core tubes. Clamp off the heater hoses to forestall lack of coolant. Refer to Cooling for the procedures. Install plugs in, or tape over the opened heater core tubes.
7. Remove the bolt from the HVAC housing mounting stud on the engine compartment facet of the sprint panel (Fig. 9).
8. Remove the rear ground warmth ducts from the ground warmth duct shops (Fig. 10).
9. Remove the HVAC housing mounting nuts from the studs on the passenger compartment facet of the sprint panel (Fig. 11).
10. Remove the HVAC housing from the car, making certain that the inside is roofed in case of lack of fluids.
DISASSEMBLY
1. Place the HVAC housing with the tubing facet down on a piece bench, making allowance for leakage of fluids.
2. Using a pointy knife, cut up the froth seal surrounding the panel outlet opening, on the dividing line of the higher and decrease instances (Fig. 12).
3. Place the HVAC housing within the upright place on the work bench.
4. Remove the mode door actuator on the left facet of the housing, which controls the mode door within the high of the case (Fig. 13) (Fig. 14).
5. Remove the screw with plastic washer holding the lever assembly to the higher case part, and transfer apart (Fig. 15).
6. Remove the 5 clips that safe the 2 housing halves to one another. There are 2 on both facet on the heart, and 1 situated on the ahead finish of the mode door facet of the case (Fig. 16).
7. Release the wire harness electrical connector(s) from the mounts on the decrease case on the blower motor finish of the unit (Fig. 17).
8. Remove the ten screws that safe the 2 housing halves to one another.
9. Separate the highest half of the HVAC housing from the underside half (Fig. 18).
NOTE: The mix door sub-assembly is connected to the housing with 2 screws, and could also be eliminated for service (Fig. 19).
ASSEMBLY
1. Place the highest half of the HVAC housing on the underside half. Be sure that every of the door pivot pins align with the pivot holes within the HVAC housing.
2. Install the ten screws that safe the 2 housing halves to one another. Tighten the HVAC housing screws to 2.2 N·m (20 in. lbs.).
3. Attach the wire harness electrical connector(s) to the mounts on the decrease case on the blower motor finish of the unit.
4. Install the 5 clips that safe the 2 housing halves to one another. Check doorways for binding after replacement, and after assembly of housing.
5. Install the screw with plastic washer holding the lever assembly to the higher case part.
6. Install the mode door actuator on the left facet of the housing.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAUTIONS IN PLUMBING BEFORE PERFORMING THE FOLLOWING OPERATION.
Any kinks or sharp bends within the refrigerant plumbing will scale back the capability of the whole air-con system. Kinks and sharp bends scale back the circulation of refrigerant within the system. A great rule for the versatile hose refrigerant traces is to maintain the radius of all bends at the very least ten instances the diameter of the hose. In addition, the versatile hose refrigerant traces must be routed so they’re at the very least 80 millimeters (3 inches) from the exhaust manifold.
High pressures are produced within the refrigerant system when the air-con compressor is working. Extreme care have to be exercised to make it possible for every of the refrigerant system connections is pressure-tight and leak free. It is an effective observe to examine all versatile hose refrigerant traces at the very least annually to ensure they’re in good situation and correctly routed.
1. Position the HVAC housing to the sprint panel. Be sure that the evaporator condensate drain tube and the housing mounting studs are inserted into their right mounting holes.
2. Install the HVAC housing mounting nuts to the studs on the passenger compartment facet of the sprint panel. Tighten the nuts to 4.5 N·m (40 in. lbs.).
3. Connect the HVAC housing wire harness connectors.
4. Reinstall the rear ground warmth ducts to the middle ground warmth duct shops.
5. Install and tighten the bolt onto the HVAC housing mounting stud on the engine compartment facet of the sprint panel. Tighten the nuts to 7 N·m (60 in. lbs.).
6. Unclamp/unplug the heater core hoses and tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system. Refer to Cooling for the procedures.
7. Unplug or take away the tape from the suction line and the evaporator outlet tube fittings. Connect the suction line to the evaporator outlet tube. Tighten retaining nut to twenty-eight N·m (250 in. lbs.).
8. Evacuate the refrigerant system.
10. Charge the refrigerant system.
11. Install the instrument panel within the car
12. Connect the battery damaging cable.
13. Start the engine and verify for correct operation of the heating and air-con methods.
BLEND DOOR REMOVAL
1. Remove evaporator from decrease case to ease entry to plastic door shaft bushing.
2. Pinch the retention tabs holding the mix door pivot shaft to the case. The 3 plastic tabs, situated on the within of the case, are a part of the shaft retainer.
3. Remove door(s).
BLEND DOOR INSTALLATION
1. Install the mix door(s) by snapping the pivot shaft into the HVAC case.
2. Install the evaporator within the decrease case.
3. Reassemble the HVAC housing and set up within the car.
NOTE: The mix door sub-assembly is connected to the housing with 2 screws, and could also be eliminated for service (Fig. 19).
MODE DOOR REMOVAL
1. Pinch the retention tabs holding the panel outlet door pivot shaft to the case. The 3 plastic tabs, situated on the within of the case, are a part of the shaft retainer (Fig. 21).
2. Using a trim stick or one other appropriate large flat-bladed device, gently pry the panel outlet door pivot shaft retainer from the pivot shaft.
3. Remove the panel outlet door from the HVAC housing.
REMOVAL – HEAT/DEFROST DOOR
1. Remove the evaporator, and styrofoam tray from the decrease case.
2. Place the HVAC housing the wrong way up on a piece bench.
3. Unscrew and take away the two ground warmth ducts.
4. Unsnap and take away the duct adapter from the underside of the warmth/defrost door sub-assembly (Fig. 22).
5. Gently pry the metallic linkage from the warmth/defrost door lever.
6. Remove the warmth/defrost door sub-assembly, which is connected to the housing with 4 screws (Fig. 23).
7. Pinch the retention tabs holding the warmth/defrost door pivot shaft lever to the case. The 3 plastic tabs, situated on the within of the case, are a part of the shaft retainer.
8. Remove the warmth/defrost door (Fig. 24).
REMOVAL – PANEL/DEFROST DOOR
1. Pinch the retention tabs holding the panel/defrost door pivot shaft to the case. The 3 plastic tabs, situated on the within of the case, are a part of the shaft retainer (Fig. 25).
2. Using a trim stick or one other appropriate large flat-bladed device, gently pry the panel/defrost door pivot shaft retainer from the pivot shaft.
3. Remove the panel/defrost door from the HVAC housing.
INSTALLATION – PANEL/DEFROST DOOR
1. Snap the panel/defrost door pivot shaft retainer on the pivot shaft.
2. Attach the panel/defrost door pivot shaft to the HVAC case.
INSTALLATION – PANEL OUTLET DOOR
1. Snap the panel outlet door pivot shaft retainer on the pivot shaft.
2. Attach the panel outlet door pivot shaft to the HVAC case.
INSTALLATION – HEAT/DEFROST DOOR
1. Install the warmth/defrost door by snapping the warmth/defrost door pivot shaft into the HVAC case.
2. Install the warmth/defrost door sub-assembly and tighten the mounting screws to 2.2 N·m (20 in. lbs.).
3. Attach the metallic linkage to the warmth/defrost door lever.
4. Snap the duct adapter to the underside of the warmth/defrost door sub-assembly.
5. Install the two ground warmth ducts and tighten the mounting screws to 2.2 N·m (20 in. lbs.).
6. Install the evaporator, and styrofoam tray within the decrease case.
RECIRCULATION DOOR REMOVAL
1. Place the HVAC housing proper facet up on the work bench.
2. Unplug the wire/vacuum connector from the recirculation door actuator.
3. Remove the two screws fastening the recirculation door sub-assembly to the primary housing (Fig. 26).
4. Raise the entrance of the door sub-assembly whereas releasing the two tabs holding the rear to the primary housing, and take away the recirculation door housing.
5. Remove the electrical/vacuum actuator from the recirculation door sub-assembly and put aside.
6. Pinch the retention tabs holding the recirculation door pivot shaft to the case. The 3 plastic tabs, situated on the within of the case, are a part of the shaft retainer.
7. Remove the recirculation door from the recirculation air door housing.
RECIRCULATION DOOR INSTALLATION
1. Install the recirculation door within the recirculation air door housing by snapping the pivot shaft retention tabs into the case.
2. Install the electrical/vacuum actuator on the recirculation door sub-assembly. Check door for binding after replacement.
3. Install the recirculation door housing on the HVAC case and tighten the two screws to 2.2 N·m (20 in. lbs.).
4. Plug within the wire/vacuum connector to the recirculation door actuator.
