Housing Assembly HVAC: Service and Repair

HVAC Module Assembly Replacement

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure




1. Recover the refrigerant from the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging.
2. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill LZ9) Draining and Filling Cooling System (Vac-N-Fill).

Important: The defroster door must be closed to allow clearance during defroster duct removal.

3. Set the heating, ventilation and air conditioning (HVAC) controls in the vent setting to close the defroster door.
4. Remove the blower motor.
5. Disconnect the electrical connector from the blower motor resistor.
6. Disconnect the electrical connector from the evaporator temperature sensor.
7. Disconnect all of the HVAC actuator electrical connectors.
8. Remove the instrument panel (I/P) carrier.
9. Remove the evaporator outlet tube nut.
10. Disconnect the evaporator outlet tube and evaporator inlet tube from the thermal expansion valve (TXV).
11. Remove and discard the sealing washers.




12. Remove the heater inlet and outlet hoses.
13. Remove the HVAC module nuts.

Installation Procedure

Important: Ensure proper alignment of the HVAC module and drain tube through the cowl.

1. Install the HVAC module.






Notice: Refer to Fastener Notice.

2. Instal the HVAC module to dash panel sound barrier nuts.

Tighten the nuts to 10 N.m (89 lb in).

3. Install the heater inlet and outlet hoses.




4. Install NEW sealing washers.
5. Connect the evaporator inlet and outlet tube block to the TXV.
6. Install the evaporator tube block nut.

Tighten the nut to 16 N.m (12 lb ft).

7. Install the I/P carrier.
8. Connect all of the HVAC actuator electrical connectors.
9. Connect the electrical connector to the evaporator temperature sensor.
10. Connect the electrical connector to the blower motor resistor.
11. Install the blower motor.
12. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill LZ9) Draining and Filling Cooling System (Vac-N-Fill).
13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
14. Leak test the fittings using the J 39400-A.