Housing Assembly HVAC: Service and Repair

HVAC MODULE ASSEMBLY REPLACEMENT

TOOLS REQUIRED
- J 39400-A Halogen Leak Detector
- J 38185 Hose Clamp Pliers

REMOVAL PROCEDURE
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the instrument panel trim pad.
4. Remove the passenger side SIR inflator module.
5. Remove the brake pedal.
6. Disconnect any ground wires, as necessary.
7. Remove the nuts and bolts from the steering column support bracket.
8. Remove the steering column support bracket from the cross vehicle beam.




9. Remove the screws from the right and left side air distribution duct.
10. Remove the right and left side air distribution duct.




11. Remove the bolts from the relay bracket and position the relay bracket aside.




12. Remove the bolts from the body control module (BCM) bracket and position the BCM bracket aside.
13. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
14. Remove the 2 screws below the fuse block that support the main wire harness connector to the cross vehicle beam.




15. Remove the bolts from the center support bracket of the HVAC module assembly.
16. Remove the center support bracket from the HVAC module assembly.




17. Remove the bolts from the upper support brackets of the HVAC module assembly.




18. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.




19. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.




20. Remove the bolt (1) from the cross vehicle beam.
21. Remove the cross vehicle beam from the vehicle.




22. Remove the accumulator tube to evaporator core block fitting bolt.
23. Disconnect the accumulator tube from the evaporator.
24. Disconnect the evaporator tube from the evaporator.
25. Remove the O-ring seals and discard.




26. Use J 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
27. Disconnect the inlet and outlet heater hose from the heater core.




28. Remove the screws from the heater core outlet cover.

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

29. Remove the heater core outlet cover.




30. Remove the evaporator drain elbow.




31. Remove the mounting nuts for the HVAC module assembly from the cowl.
32. Disconnect the vacuum hoses from the HVAC module assembly.
33. Disconnect the electrical connectors from the HVAC module assembly.
34. Remove the HVAC module assembly.




35. Remove all of the seals (1, 2, 3) from the outer HVAC module assembly.

INSTALLATION PROCEDURE




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




3. Install the nuts which secure the HVAC module assembly to the dash.

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

NOTE: Refer to Fastener Notice in Service Precautions.




4. Install the evaporator drain elbow.
5. Connect the electrical connectors to the HVAC module assembly.
6. Connect the vacuum hoses to the HVAC module assembly.




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

Tighten the screws to 1.5 N.m (13 lb in).




9. Install the cross vehicle beam to the vehicle.




10. Install the bolts which secure the right cross vehicle beam to the hinge pillar.

IMPORTANT: Do NOT tighten the bolts at this time.




11. Install the bolts which secure the left cross vehicle beam to the hinge pillar.

Tighten the bolts to 20 N.m (15 lb ft).




12. Install the bolt (1) to the cross vehicle beam.

Tighten the bolt to 20 N.m (15 lb ft).




13. Install the bolts to the upper support brackets of the HVAC module.

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




14. Install the center support bracket to the HVAC module assembly.
15. Install the bolts to the center support bracket of the HVAC module assembly.

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

16. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.
17. Install the 2 screws below the fuse block that support the main wire harness connector to the cross vehicle beam.




18. Install the BCM bracket and the bolts.

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




19. Install the relay bracket and the bolts.

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




20. Install the right and left side air distribution ducts.
21. Install the screws to the right and left side air distribution duct.

Tighten the screws to 1.5 N.m (13 lb in).

22. Install the steering column support bracket to the cross vehicle beam.




23. Install the steering column support bracket nuts and bolts.

Tighten the nuts and bolts to 50 N.m (37 lb ft).

24. Install the brake pedal.
25. Connect all disconnected ground wires.
26. Install the passenger side SIR inflator module.
27. Install the instrument panel trim pad.




28. Connect the inlet and outlet heater hose to the heater core.

IMPORTANT: Reposition the heater core hose clamps in the indicated location.

29. Use J 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.




30. Connect the evaporator tube to the evaporator.
31. Connect the accumulator tube to the evaporator.
32. Install the accumulator tube to evaporator core block fitting bolt.

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

33. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
34. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
35. Leak test the fittings of the component using J 39400-A.