HVAC Systems (Service Information): Distribution: Housing-HVAC: Installation: Housing-HVAC

Fig 1: Housing - HVAC - Installation Fasteners

Courtesy of DAIMLERCHRYSLER CORP.

NOTE: LHD model shown in illustration. RHD model similar.

1. Position the HVAC housing assembly to the dash panel (2). Be certain that the condensate drain and the housing mounting studs are inserted into their correct locations.
2. Install the bolt (3) that secures the air inlet housing (4) to the passenger compartment side of dash panel. Tighten the bolt to 4.5 N.m (40 in. lbs.).
3. Install the bolt (5) that secures the HVAC housing (7) to the floor bracket (6). Tighten the bolt to 4.5 N.m (40 in. lbs.).
4. Install the right rear floor duct (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/DUCTS-FLOOR DISTRIBUTION - INSTALLATION) .
5. Reposition the dash panel insulator (1) and install the instrument panel (Refer to BODY/INSTRUMENT PANEL/ASSEMBLY-INSTRUMENT PANEL - INSTALLATION) .
   Fig 2: Dash Panel - LHD Shown, RHD Typical

   Courtesy of DAIMLERCHRYSLER CORP.
   NOTE: LHD model shown in illustration. RHD model similar.
6. Install the three nuts(6) that secure the HVAC housing to the engine compartment side of the dash panel (4). Tighten the nuts to 4.5 N.m (40 in. lbs.).
7. Remove the previously installed plugs or caps and connect the heater hoses (5) to the heater core tubes.
8. Install the condensation drain tube (3) (Refer to HEATING & AIR CONDITIONING/PLUMBING/TUBE-CONDENSATION DRAIN - INSTALLATION) .
9. Remove the previously installed plugs or caps and connect the refrigerant lines to the A/C evaporator (2) and A/C accumulator using new O-ring seals (Refer to HEATING & AIR CONDITIONING/PLUMBING /LINE-A/C LIQUID - INSTALLATION)  and (Refer to HEATING & AIR CONDITIONING/PLUMBING/ACCUMULATOR-A/C - INSTALLATION) .
10. Install the coolant recovery container, (Refer to COOLING/ENGINE/COOLANT RECOVERY CONTAINER - INSTALLATION) .
11. Install the air filter housing and air inlet tube:
    • 1.6L, (Refer to ENGINE/AIR INTAKE SYSTEM/ELEMENT-AIR CLEANER - INSTALLATION) .
    • 2.4L, (Refer to ENGINE/AIR INTAKE SYSTEM/ELEMENT-AIR CLEANER - INSTALLATION) .
12. Reconnect the negative battery cable.
13. If the heater core is being replaced, flush the cooling system, (Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING) .
14. Refill the engine cooling system, (Refer to COOLING/ENGINE - STANDARD PROCEDURE - COOLING SYSTEM FILL) .
15. Evacuate the refrigerant system, (Refer to REFRIGERANT SYSTEM EVACUATE) .
16. Charge the refrigerant system, (Refer to REFRIGERANT SYSTEM CHARGE) .