For 1990-2009 cars

## Air Inlet Assembly Replacement RHD

### Removal Procedure

Caution: Refer to Safety Glasses Caution in the Preface section.

1. Remove the instrument panel (I/P). Refer to Instrument Panel Center Trim Panel Replacement .
2. Remove the thermal expansion (TX) valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement
3. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
4. With the HVAC module assembly on a bench locate the TX valve retaining upper plastic cover (1).

Important: Unclip the TX valve retaining upper plastic cover (1) and remove by lifting upwards.

5. Remove the TX valve retaining upper plastic cover (1).
6. Remove the air inlet assembly to HVAC module assembly retaining screws (1).
7. Remove the air inlet assembly to HVAC module assembly retaining screws (1).

Important: Unclip the air inlet assembly (3) and carefully tilt downwards past the TX valve (2)

8. Remove the air inlet assembly (3) from the HVAC module assembly (1).

### Installation Procedure

1. Install the air inlet assembly (2) to the HVAC module assembly (1).

Notice: Refer to Fastener Notice in the Preface section.

2. Install the air inlet assembly to HVAC module assembly retaining screws (1).

Tighten
Tighten the screws to 1 N·m (8 lb in.)

3. Install the air inlet assembly to HVAC module assembly retaining screws (1).

Tighten
Tighten the screws to 1 N·m (8 lb in.)

Important: Make sure all the clips on the thermal expansion (TX) valve retaining upper plastic cover (1) are engaged to avoid an induced rattle condition.

4. Install the TX valve retaining upper plastic cover (1).
5. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
6. Install the TX valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement
7. Install the instrument panel (I/P). Refer to Instrument Panel Center Trim Panel Replacement .