Housing Assembly HVAC: Service and Repair

Air Conditioning and Heater Module Assembly Removal and Installation

Special Tools

J 38185 - Hose Clamp Pliers

Removal Procedure

Warning: Refer to Safety Glasses Warning Safety Glasses Warning.


1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

Warning: Refer to Battery Disconnect Warning Battery Disconnect Warning.


2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).

3. Remove the windscreen wiper arms. Refer to Windshield Wiper Arm Replacement Service and Repair.

4. Remove the air inlet grill panel. Refer to Air Inlet Grille Panel Replacement (Lower Panel) Air Inlet Grille Panel Replacement (Lower Panel)Air Inlet Grille Panel Replacement (Upper Panel) Air Inlet Grille Panel Replacement (Upper Panel).

5. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.





Note: Mark position of heater hoses (3) and heater hose retaining clamps (1) before removal to make sure of correct alignment during assembly.

6. Using J 38185 - Hose Clamp Pliers, compress the heater hose retaining clamps (1) and slide along the heater hose (3).

7. Remove the heater hoses (3) from the heater core pipes (2).




8. Disconnect the vacuum hose (1) and the vacuum brake booster check valve (3) from the vacuum brake booster (2).

9. Detach the vacuum hose (1) from the bulkhead mounted vacuum hose retaining bracket (4) and position aside.




10. Remove the remote battery positive post cover (1).




11. Remove the remote battery positive post to wiring harness retaining bolt (1).

12. Remove the starter motor power cable (2) and position aside.




13. Remove the suction pipe upper to suction pipe lower retaining nut (1).




14. Remove the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).

15. Detach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).




16. Disconnect the suction pipe upper (1) from suction pipe lower (2).

Note: The sealing washer (3) is a single use item and must be discarded after use.

17. Remove the sealing washer (3). Refer to Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement.
Discard the sealing washer.

Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

18. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).




19. Remove the suction pipe/liquid pipe pad to TX valve retaining nut (1).




20. Disconnect the suction pipe/liquid pipe pad (3) from the TX valve (1).

Note: The sealing washers (2) are a single use item and must be discarded after use.

21. Remove the sealing washers (2). Refer to Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement.
Discard the sealing washers.

Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

22. Cap or plug the suction pipe (4), liquid pipe (5) and the TX valve (1).




23. Remove the HVAC to bulkhead retaining bolts (1).




24. Disconnect the blower motor electrical connector (2).

25. Disconnect the HVAC module electrical connectors (3).

26. Disconnect the blower motor control processor electrical connector (1).

27. Detach the I/P wiring harness to HVAC module assembly retaining clips (4).

28. Remove the instrument panel (I/P) pad. Refer to Instrument Panel Upper Trim Pad Replacement Instrument Panel Upper Trim Pad Replacement.

29. Remove the instrument panel centre support bracket. Refer to Instrument Panel Tie Bar Replacement (9C3) Instrument Panel Tie Bar Replacement (9C3)Instrument Panel Tie Bar Replacement (9C1) Instrument Panel Tie Bar Replacement (9C1).




30. Remove the HVAC module assembly to I/P carrier retaining bolts (1).




31. Remove the HVAC module assembly to I/P carrier retaining bolts (1).

32. Remove the I/P carrier. Refer to Instrument Panel Carrier Replacement Instrument Panel Carrier Replacement.





Note: To remove the HVAC module assembly (2) from the vehicle (1) rotate the HVAC module assembly (2) downwards and towards the back of the vehicle (1).

33. Remove the HVAC module assembly (2) from the vehicle body (1).

Installation Procedure





Note: To install the HVAC module assembly (2) to the vehicle (1) rotate the HVAC module assembly (2) upwards and towards the front of the vehicle (1).

Note: Make sure the HVAC module assembly (3) fits into the drain assembly

1. Install the HVAC module assembly (1) to the vehicle body (2).

2. Install the I/P carrier. Refer to Instrument Panel Carrier Replacement Instrument Panel Carrier Replacement.





Caution: Refer to Fastener Caution Fastener Caution.

3. Install the HVAC module assembly to I/P carrier retaining bolts (1) and tighten to 9 Nm (80 lb in).




4. Install the HVAC module assembly to I/P carrier retaining bolts (1) and tighten to 9 Nm (80 lb in).




5. Install the HVAC module assembly to bulkhead retaining bolts (1) and tighten to 7 Nm (62 lb in).




6. Connect the blower motor control processor electrical connector (1).

7. Connect the HVAC module electrical connectors (3).

8. Connect the blower motor electrical connector (2).

9. Attach the I/P wiring harness to HVAC module assembly retaining clips (4).

10. Install the I/P upper trim pad. Refer to Instrument Panel Upper Trim Pad Replacement Instrument Panel Upper Trim Pad Replacement.

11. Install the I/P retainer bracket. Refer to Instrument Panel Tie Bar Replacement (9C3) Instrument Panel Tie Bar Replacement (9C3)Instrument Panel Tie Bar Replacement (9C1) Instrument Panel Tie Bar Replacement (9C1).




12. Remove the plugs or caps from the suction pipe (4), liquid pipe (5) and the TX valve (1).

Note: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

13. Install NEW sealing washers (2). Refer to Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement.

14. Position the suction pipe/liquid pipe pad (3) to the TX Valve (1).




15. Install the suction pipe/liquid pipe pad to TX valve retaining nut (1) and tighten to 22 Nm (16 lb ft).




16. Remove the plugs or caps from the suction pipe upper (1) and the suction pipe lower (2).

Note: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

17. Install a NEW sealing washer (3). Refer to Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement.

18. Install the suction pipe upper (1) to the suction pipe lower (2).




19. Attach the liquid pipe (1) to the suction pipe/liquid pipe retaining clip (2).

20. Install the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).




21. Install the suction pipe upper to suction pipe lower retaining nut (1) and tighten to 22 Nm (16 lb ft).




22. Install the starter motor positive cable (2) to the remote battery positive post (3).

23. Install the remote battery positive post to wiring harness retaining bolt (1) and tighten to 15 Nm (11 lb ft).





Note: Make sure the clips on the remote battery positive post cover (1) are engaged to avoid an induced rattle condition.

24. Install the remote battery positive post cover (1).




25. Connect the vacuum hose (1) and the vacuum brake booster check valve (3) to the vacuum brake booster (2).

26. Attach the vacuum hose (1) to the bulkhead mounted vacuum hose retaining bracket (4).





Note: If reusing the heater hoses (3), align the heater hoses (3) with the marks made on the heater core inlet pipe (2) during the removal procedure.

27. Connect the heater hoses (3) to the heater core pipes (2).

28. Using J 38185 - Hose Clamp Pliers, slide the heater hose retaining clamps (1) back into the original position on the heater hoses (3).

29. Install windscreen wiper arms. Refer to Windshield Wiper Arm Replacement Service and Repair.

30. Install the air inlet grill panel. Refer to Air Inlet Grille Panel Replacement (Lower Panel) Air Inlet Grille Panel Replacement (Lower Panel)Air Inlet Grille Panel Replacement (Upper Panel) Air Inlet Grille Panel Replacement (Upper Panel).

31. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).

32. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

Note: The receiver and dehydrator is a single use only component. A NEW receiver and dehydrator must be installed whenever a closed A/C system is opened or exposed to atmosphere. If the receiver and dehydrator has been replaced following a service/repair and it is deemed necessary to immediately re-open the A/C system it is not necessary to replace the receiver and dehydrator again, providing the A/C system is plugged/capped correctly.

33. Replace the receiver and dehydrator. Refer to Receiver and Dehydrator Replacement Service and Repair.

34. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

35. Leak test the HVAC module assembly pipe connections. Refer to Leak Testing Leak Testing.