25/05/2022 09:09:45

HVAC Assembly (Remove and Replace)

Correction Code 18101002

Removal

  1. Position the vehicle so that both front doors can be fully opened.
  2. Move the driver's seat fully rearwards.
  3. Move the passenger's seat fully rearwards.
  4. Move the steering column to the lowest position, and fully extended.
  5. Open the glove box.
  6. Recover refrigerant from the vehicle (refer to procedure).
  7. Perform the vehicle HV disablement procedure (refer to procedure).
  8. Remove the cross car beam (refer to procedure).
  9. Remove the RH shock tower brace (refer to procedure).
  10. Vehicles with air suspension only:
    1. Release the screws (x2) that secure the air reservoir (torque 2.5 Nm). Carefully move the reservoir out of the working area.
      Informational PurposesAn informational icon, calling your attention
      Note
      It is not necessary to disconnect the air lines.
    2. Remove the RH air suspension reservoir bracket.
  11. Remove the bolt that secures the A/C pipe to the bulkhead TXV valve (torque 22 Nm).
  12. Remove and discard the O-rings.
  13. Disconnect the TXV harness connector.
  14. Remove the screws (x2) that secure the bulkhead TXV valve to the HVAC assembly (torque 6 Nm).
  15. Remove and discard the O-ring.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Lubricate new O-rings with clean refrigerant oil.
  16. Working from above, disconnect the PTC heater harness from the DCDC converter or forward junction box.
    Informational PurposesAn informational icon, calling your attention
    Note
    Components have been removed in this graphic to aid clarity.
    1 HV Battery heater harness
    2 DCDC converter harness
    3 Compressor harness
    4 PTC heater harness
  17. Attach string or wire to the PTC heater harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    The string/wire will make it easier to re-install the PTC heater later.
  18. Release the PTC heater harness from the HVAC retaining clip.
  19. With assistance, carefully release the PTC heater harness from the bulkhead and carefully pull it into the vehicle through the footwell.
  20. Remove the string/wire from the PTC heater harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not withdraw the string/wire from the bulkhead.
  21. Disconnect the electrical connectors from the HVAC assembly.
  22. LHD vehicles only: Remove the body controller (BCM) (refer to procedure).
  23. Remove the bolts (x7) that secure the HVAC assembly to the bulkhead (torque 6 Nm).
  24. Disconnect the HVAC drain tube.
  25. Carefully remove the HVAC assembly.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Plug pipe connections to prevent ingress of moisture or dirt.

Installation

Installation procedure is the reverse of removal, except for the following:
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Lubricate new O-rings with clean refrigerant oil.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
When reinstalling the cross car beam, ensure that the wiring harness is not pinched between the beam and the PTC heater.
  • Secure the string/wire to the PTC heater harness. With assistance, carefully pull the harness through the bulkhead. Ensure that the surrounding components are not compromised. Use a cable tie and a clip harness to avoid rubbing.
  • Reinstall the latest vehicle firmware, or update the firmware if not the latest. See Firmware Reinstall - Touchscreen or Firmware Update.