Bench Overhaul - HVAC Module (RHD Domestic Only)

BENCH OVERHAUL - HVAC MODULE (RHD DOMESTIC ONLY)

REMOVAL




1. Remove pipe cover screws and remove pipe cover.




2. Remove pipe support plate screws and remove support plate.

IMPORTANT: Be careful not to spill any residual coolant from heater core when removing.




3. Remove heater core assembly from module case.




4. Remove left module mounting bracket screws and remove mounting bracket.




5. Release temperature cable from retainer clip by pushing upward on upper tab of clip while pulling outward on cable housing.




6. Remove temperature cable circular push-on retainer.
7. Remove temperature cable from temperature cam.




8. Use a small flat blade screwdriver to gently pry back upper mix lever center tab and pull upper mix lever off shaft.




9. Remove temperature cam screw and washer and remove cam.




10. Use a small flat blade screwdriver to gently pry back lower mix lever center tab and pull lower lever off shaft.




11. Remove mode cable from retainer clip by pressing upward on upper tab while pulling outward on cable housing.




12. Remove mode cam screw and washer and pull cam outward to disengage mode cable eyelet.




13. Remove defroster door sub-lever screw and washer and remove lever.




14. Remove heater door sub-lever screw and washer and remove lever.




15. Using a small flat blade screwdriver, gently pry back center tabs and pull defroster lever, vent lever, and heater lever off of shafts.




16. Remove lower case screws and remove lower case.




17. Use a razor blade to carefully cut defroster and vent foam seals at centerline.

IMPORTANT: One screw is located in deep cavity to the right of the mix cam.




18. Remove case screws and lift straight up to separate the two halves of the case.




19. Remove the evaporator core.

INSTALLATION

NOTE: When installing a new evaporator core, 67 ml (2.25 oz.) of PAG oil must be added to the core. Replace the evaporator pipe cover before installing core.




1. Install the evaporator core into the right side of HVAC module case.

NOTE: Left case half cross support must interlock with right case half cross support.

IMPORTANT: When properly seated, module case tongue and groove seal will fit together snugly.




2. Install left half of HVAC module ease over core and align door shafts with openings. Press halves together until seated.




3. Install case screws. When installing center screw, use a piece of tape to hold screw to socket until threads are started.

IMPORTANT: When properly seated, module case tongue and groove seal will fit together snugly.




4. Install lower case.
5. Install lower case screws.




6. Install heater core assembly. Press core into HVAC module case until pipes contact pipe cover attachment boss.




7. Install heater core pipe cover and screws.





IMPORTANT: All plastic cam levers have molded in part names and numbers. Refer to the cam illustration chart for part location information. All levers must be installed with the retention tang outward. Applying pressure to the opposite end of the door shaft may aid in seating tang into shaft notch.




8. Install defroster lever labeled "DEF" onto defroster door shaft until tang seats into shaft notch.
9. Install vent lever labeled "VENT 1301" onto vent door shaft until tang seats into shaft notch.
10. Install heater lever labeled "VENT 1401" onto heater door shaft until tang seats into shaft notch.




11. Position metal heater sub-lever on module boss with pin set into heater door lever.
12. Install heater sub-lever washer and screw.
13. Rotate heater sub-lever to verify the smooth operation of the levers and heater door.




14. Position metal defroster sub-lever on module boss with pins set into defroster door lever.
15. Install defroster sub-lever washer and screw.
16. Rotate defroster sub-lever to verify the smooth operation of the lever and defroster door.




17. Install mode cam on center boss. Align defroster sub-lever, vent lever, and heater sub-lever so that each pin is the proper mode cam track.
18. Install mode cam washer and screw.
19. Rotate mode cam to verify the smooth operation of all doors, levers, and sub-levers.





IMPORTANT:
^ Install mode cable with wire eyelet wrap as shown.
^ Do not install mode cable housing into retainer at this time.




20. Install mode cable eyelet between mode cam pin and module case and rotate onto mode cam pin.




21. Install lever labeled "HOT" onto lower mix cam door shaft until tang seats into shaft notch.




22. Install temperature cam ensuring that lower mix lever pin is in earn lower track.
23. Install temperature earn washer and screw.




24. Position lever labeled "COOL" onto upper mix earn door shaft so that pin Will be in upper temperature cam track when seated. Press down until tang seats into shaft notch.
25. Rotate temperature cam to verify the smooth operation of both doors.





IMPORTANT:
^ Install temperature cable with wire eyelet wrap as shown.
^ Do not install temperature cable housing into retainer clip at this time.




26. Install temperature cable on temperature cam pin and install circular push-on retainer.




27. Install left module mounting bracket and screws.




28. Install pipe support plate and screws.




29. Install evaporator block seal, heater core pipe seal, and drain tube seal.

IMPORTANT: The heater core pipe seal consists of two seals installed back to back.