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HVAC Housing







HOUSING-HVAC ASSEMBLY

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemRefrigerant Oil Level .

NOTE: If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.





1. If removed, install the insulator (3) over the A/C evaporator (2). If the seal is deformed or damaged, it must be replaced.
2. If removed, install the rubber seal (1) into the lower half of the HVAC housing (4). If the seal is deformed or damaged, it must be replaced.
3. Install the A/C evaporator into the lower half of the HVAC housing. Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and that the insulator and rubber seal are properly installed.





4. Install the upper half of the HVAC housing (3) onto the lower half of the HVAC housing (4) and fully engage the two plastic retaining clips (7).
5. Install the ten screws (6) that secure the two halves of the HVAC housing together. Tighten the screws to 2.2 Nm (20 in lbs.).
6. Install the three metal retaining clips (5) that secure the two halves of the HVAC housing together.





7. Remove the tape or plugs from the evaporator tube fittings and all of the expansion valve ports.
8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator tube fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
9. Install the A/C expansion valve (2) onto the evaporator tube tapping block (3) located at the front of the HVAC housing (4).
10. Install the two bolts (1) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 Nm (97 in. lbs.).





11. Install the evaporator temperature sensor (2) Evaporator Temperature Sensor - Installation.
12. Install the blower motor resistor or power module (4), depending on application Installation or Blower Motor Power Module - Installation.
13. Install the blower motor (3) Installation.
14. Install the HVAC wiring harness (1) onto the HVAC housing (5) and engage the two wire harness retainers to the housing.
15. Connect the HVAC wire harness to the evaporator temperature sensor and blower motor resistor or power module (depending on application).
16. Connect the blower motor wire harness to blower motor resistor or power module (depending on application).





17. Install the air inlet housing (2) onto the HVAC housing (1) HVAC Housing - Installation.
18. Install the air distribution housing (3) onto the HVAC housing HVAC Housing - Installation.
19. Install the HVAC housing assembly HVAC Housing - Installation.
20. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

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