Housing Assembly HVAC: Service and Repair

HVAC MODULE ASSEMBLY REPLACEMENT

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant.
2. Disconnect the battery negative cable.
3. Drain the cooling system.
4. Remove the instrument panel pad.
5. Remove the inflatable instrument panel restraint module.
6. Remove the right side HVAC duct from the HVAC unit.
7. Remove the lower radio bracket.
8. Remove the instrument panel right end bracket.
9. Remove the instrument panel center support bracket.
10. Remove the radio antenna lead from the three retaining clips on the HVAC unit.
11. Mark and remove the heater hoses from the heater core pipes.
12. Disconnect the water valve vacuum hose.
13. Disconnect the vacuum supply hose from the check valve.
14. Remove the Thermal Expansion Valve (TXV).
15. Remove the fuel line retaining bracket and nut from the HVAC mounting stud.
16. Remove the HVAC unit mounting stud and screws.
17. Remove the HVAC unit from the vehicle.

Installation Procedure
1. Install the HVAC module assembly to the vehicle.

NOTICE: Refer to Fastener Notice in Service Precautions.

2. Install the screws from inside the vehicle which secure the HVAC module assembly to the dash.

Tighten
Tighten the nuts to 6 N.m (53 Ib in).

3. Install the screws from inside the engine compartment which secure the HVAC module assembly to the dash.

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

4. Install the fuel line retaining bracket and nut to the HVAC mounting stud.

Tighten
Tighten the nut to 10 N.m (89 Ib in).

5. Install the Thermal Expansion Valve (TXV).
6. Connect the vacuum supply hose to the check valve.
7. Connect the water valve vacuum hose.
8. Install the heater hoses to the heater core pipes.
9. Install the radio antenna lead to the three retaining clips on the HVAC unit.
10. Install the instrument panel center support bracket.
11. Install the instrument panel right end bracket.
12. Install the lower radio bracket.
13. Install the right side HVAC duct to the HVAC unit.
14. Install the inflatable instrument panel restraint module.
15. Install the instrument panel pad.
16. Connect the battery negative cable.
17. Fill the cooling system.
18. Evacuate and recharge the A/C system.
19. Leak test the fittings of the component using J 39400-A.