Heating and A/C Unit, Removing and Installing

Heating And A/C Unit, Removing And Installing







Assembly overview
1. Heating and A/C unit
Contains:
- Heater core
- Evaporator
2. Screws
- 12 Nm
3. Screw
- 3.5 Nm
4. Instrument panel cross member
- Always follow installation instructions for bolt, see Fig. 7
5. Support
6. Footwell vent assembly

Heating and A/C unit, removing and installing

NOTE:
- Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures.
- Service refrigerant system using Kent More ACR 4 or equivalent
- During servicing, all couplings, fittings and related fasteners must be torqued to specifications.

Removing
- Discharge refrigerant system.
- Drain engine coolant.
- Remove instrument panel.
- Remove coolant hoses at heater core, see Fig. 1.
- Seal off inlet and outlet at heater core to prevent coolant from escaping.
- Remove refrigerant lines at evaporator, see Fig. 2.
- Remove Heating and A/C unit mounting screws -2- and -3-.
- Remove footwell vent assembly -6-
- Remove support -5-.
- Disconnect all electrical connections and wiring harness tie straps at heating and A/C unit.
- Carefully pull out and remove complete housing -1- from vehicle.
- Loosen instrument panel cross member -4- if necessary.

Assembly

Installing
- Install in reverse order of removal, noting the following:

NOTE:
- Inspect all heating and A/C unit housing seals for damage and replace if necessary before installation. Evaporator inlet/outlet seal, see Fig. 2. Evaporator seal, see Fig. 3.
- Ensure all electrical harness tie straps are replaced and installed in their original locations.
- Replace both evaporator inlet/outlet O-rings.
- Ensure refrigerant pipes are reinstalled stress free.
- Ensure evaporator water drain and drain valve are installed and function properly, see below Fig. _1.
- Evacuate and recharge refrigerant system.
- Perform leak test.







Fig. 1 Coolant hoses at heater core, removing
- Note Installation orientation of coolant hoses -A- (inlet and outlet) in engine compartment.
- Clamp off both coolant hoses to heater core using 3094 hose clamps (or equivalent).
- Release both coolant hose clamps using suitable pliers and pull hoses off from heater core inlet and outlet.







Fig. 2 Refrigerant lines at evaporator, removing

- Remove screw -3- (15 Nm).
- Gently rock flange with refrigerant lines -2- up and down until they release from evaporator.

CAUTION: Immediately plug open connections on A/C components and lines to prevent dirt and moisture contamination.

NOTE: Always replace both O-rings -1-