Housing Assembly HVAC: Service and Repair

HVAC MODULE ASSEMBLY REPLACEMENT

Tool Required
- J 39400-A Halogen Leak Detector

REMOVAL PROCEDURE

1. Recover the refrigerant.
2. Remove the cross vehicle brace. Cross Vehicle Brace Replacement
3. Drain the cooling system.
4. Remove the cross vehicle beam. Instrument Panel (IP) - Tie Bar / Cross Vehicle Beam
5. Remove the A/C lines from the evaporator block fitting.
6. Remove the heater hoses from the heater core.






IMPORTANT: Position the heater core outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly.

7. Remove the heater core outlet cover screws.
8. Remove the heater core outlet cover.






9. Remove the evaporator blower motor clog tube.






10. Remove the HVAC module assembly mounting nuts from the cowl
11. Disconnect the vacuum hoses.
12. Disconnect the electrical connectors.
13. Remove the HVAC module.






14. Remove all of the outer HVAC module seals (1,2,3).

INSTALLATION PROCEDURE






1. Install new outer HVAC module assembly seals (1, 2, 3).
2. Install the HVAC module assembly to the vehicle.







NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the HVAC module to dash nuts.

Tighten
Tighten the HVAC module nuts to 10 Nm (89 lb in).






4. Install the evaporator blower motor clog tube.
5. Connect the electrical connectors.
6. Connect the vacuum hoses.






7. Install the heater core outlet cover.
8. Install the heater core outlet cover screws.

Tighten
Tighten the heater core outlet cover screws to 1.5 Nm (13 lb in).

9. Install the cross vehicle beam. Instrument Panel (IP) - Tie Bar / Cross Vehicle Beam
10. Install the heater hoses to the heater core.
11. Install the A/C lines to the evaporator block fitting.
12. Fill the cooling system.
13. Install the cross vehicle brace. Cross Vehicle Brace Replacement
14. Evacuate and recharge the A/C system.
15. Leak test the fittings of the component using J 39400-A.