- Disconnect and isolate the negative battery cable.
- Recover the refrigerant from the refrigerant system.
- Partially drain the engine cooling system.
Remove the top nut (2) that secures the heat shield (3) to the stud (1) located on the dash panel.
NOTETwo slots are provided at the bottom of the heat shield to aid in heat shield removal. Complete removal of the two bottom heat shield retaining nuts is not required.
- Reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required.
Remove the bolt (1) that secures the A/C liquid and suction line assembly (2) to the A/C evaporator (3).
- Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals.
- Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports.
Disconnect the heater hoses (4) from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal.
NOTEMake sure to remove the five bolts that secure the HVAC housing to the instrument panel support prior to removing the instrument panel from the vehicle.
- Remove the instrument panel.
- Remove the rear floor ducts.
- Remove the condensation drain tube.
Remove the nut (1) that secures the passenger side of the HVAC housing (2) to the dash panel (3).
NOTEUse care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores.
- Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger compartment.
- Position the HVAC housing assembly to the dash panel. Be certain that the passenger side of the HVAC housing is correctly located over the dash panel mounting stud.
- Install the nut that secures the HVAC housing to the passenger compartment side of dash panel.
- Install the condensation drain tube.
- Install the rear floor ducts.
- Install the instrument panel.
- Remove the previously installed plugs or caps and connect the heater hoses to the heater core tubes.
- Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
- Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals 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.
- Connect the A/C liquid and suction line assembly to the A/C evaporator.
- Install the bolt that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 18 ft. lbs. (25 Nm).
- Position the heat shield onto the three studs located on the dash panel in the engine compartment.
- Install the three nuts that secure the heat shield to the dash panel.
- Reconnect the negative battery cable.
- If the heater core is being replaced, flush the cooling system.
- Refill the engine cooling system.
- Evacuate the refrigerant system.
- Charge the refrigerant system.
- Initiate the Actuator Calibration function using a scan tool.