HVAC System: Removal & Installation Chevrolet Prizm I

REMOVAL & INSTALLATION

Note. For removal and installation procedures not covered in this article, see HEATER SYSTEMS - PRIZM article.

Remove right kick panel and sill plate. Remove glove box. (Scheme 2) Remove screws attaching A/C compressor control module to evaporator case. Disconnect electrical connector. To install, reverse removal procedure.

Scheme 2

1. Disconnect negative battery cable. Disconnect cigarette lighter, ashtray bulb, and hazard switch electrical connectors from center trim bezel. Remove cigarette lighter and ashtray bulbs from center trim bezel. Remove center trim bezel from instrument panel.
2. Remove screws and heater control panel from instrument panel. Disconnect control cables from control panel (if necessary). Remove blower speed control knob. Remove clip, harness connector and A/C switch from control panel. (Scheme 3) To install, reverse removal procedure.

Scheme 3

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect negative battery cable. Remove accessory drive belt. Disconnect compressor electrical connector.
2. Remove refrigerant lines at compressor, and plug fittings immediately. Remove compressor upper mounting bolt. Raise and support vehicle. Remove right side splash shield and 2 compressor lower mounting bolts. Remove compressor from vehicle.
3. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-248-S04702768402000030800000) table. Install new "O" rings. When installing new compressor, add 4.1 ounces of refrigerant oil to suction side fitting of compressor. Evacuate, charge, and leak test A/C system.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect negative battery cable. Remove condenser fan assembly. See «CONDENSER FAN»(ref-248-S26385485702000030800000) . Remove discharge and liquid lines from condenser. Remove radiator brackets from vehicle. Remove 4 bolts securing A/C condenser to vehicle. Lean radiator back and pull condenser out carefully.
2. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-248-S04702768402000030800000) table. Use new "O" rings on refrigerant lines. When installing new condenser, add 2.0 ounces of refrigerant oil to suction side fitting of evaporator. Evacuate, charge, and leak test A/C system.

Disconnect negative battery cable. Drain engine coolant. Remove 2 upper radiator bracket bolts and 4 A/C condenser bracket bolts. Disconnect both fan connectors. Remove radiator hoses from radiator. Disconnect transmission cooler lines (if equipped). Remove fan shroud-to-radiator bolts and remove fan assembly. If fan assembly will not come out alone, remove radiator and fan assembly from vehicle. Remove fans and shroud from radiator. Remove fan from defective motor and remove motor from shroud. To install, reverse removal procedure.

1. Remove HVAC assembly. See «HVAC ASSEMBLY»(ref-248-S41086966712000030800000). Remove 4 screws, 2 brackets and heater core from HVAC assembly. Remove 11 screws and separate HVAC assembly case halves. see scheme 2 Remove evaporator from HVAC assembly.
2. To install, reverse removal procedure. Use new "O" rings on refrigerant lines. When installing new evaporator core, add 1.4 ounces of refrigerant oil to suction side fitting of compressor. Evacuate, charge, and leak test A/C system.

Scheme 4

1. Remove instrument panel. See HEATER SYSTEMS - PRIZM article. Disconnect A/C compressor control module connector and remove A/C compressor control module. Drain engine coolant and remove hoses from heater core. Discharge A/C system, using approved refrigerant recovery/recycling equipment.
2. Remove cruise control servo located on right rear of engine compartment. Disconnect evaporator refrigerant lines from evaporator. Remove hold-down bracket for evaporator refrigerant lines.
3. Separate rear heater ducts from HVAC assembly. Remove 6 nuts from inside passenger compartment attaching HVAC assembly to vehicle. Remove HVAC assembly from vehicle. (Scheme 4) To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-248-S04702768402000030800000) table.

1. Turn ignition switch to OFF position. Disconnect negative battery cable. Remove glove box assembly. (Scheme 2) Remove console support bracket. Remove left lower finish panel and backing panel. Remove center finish panel. Remove radio.
2. Remove 2 bolts in rear console box. Remove 2 screws on sides of center console. Raise parking brake lever. Slide rear portion of center console back toward rear seats. Remove 2 upper screws on front of console and remove front portion of console.
3. Disconnect electrical connectors from Powertrain Control Module (PCM). Remove mounting bolts from PCM. Remove PCM. (Scheme 5) To install, reverse removal procedure.

Scheme 5

Scheme 6

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect negative battery cable. Remove cruise control servo (if equipped). Disconnect refrigerant lines from receiver-drier and plug all openings. Remove bolts attaching receiver-drier to mounting bracket. (Scheme 6) Remove receiver-drier.
2. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-248-S04702768402000030800000) table. Use new "O" rings on refrigerant lines. When installing new receiver-drier, add 2.9 ounces of refrigerant oil to suction side fitting of compressor. Evacuate, charge, and leak test A/C system.