Housing Assembly HVAC: Service and Repair

Air Conditioning and Heater Module Assembly Removal and Installation

Tools Required
- J 39400-A Halogen Leak Detector

Removal Procedure






1. Recover the A/C system. Refer to Refrigerant Recovery and Recharging Service and Repair.
2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System Service and Repair.
3. Raise the vehicle.
4. Remove the evaporator hose assembly from the evaporator. Refer to Air Conditioning Evaporator Hose Assembly Replacement Service and Repair.
5. Remove the heater hoses from the heater core. Refer to Heater Hose Replacement Service and Repair.
6. Remove the drain tube elbow from the evaporator block heater case plate.






7. Remove the nuts holding the heater case plate for the heater pipes.
8. Remove the heater case plate and the seals for the heater pipes.
9. Remove the nuts holding the heater case plate for the evaporator block.
10. Remove the heater case plate and seal for the evaporator block.
11. Remove the nut for the HVAC module assembly bracket.
12. Lower the vehicle.
13. Remove the Instrument Panel (IP) carrier. Refer to Instrument Panel Trim Pad Replacement Service and Repair.
14. Remove the air distribution duct. Refer to Air Distributor Duct Replacement Service and Repair.
15. Remove the floor air duct from the HVAC module assembly.
16. Remove the cross vehicle beam (tie bar). Refer to Instrument Panel Tie Bar Replacement Service and Repair.






17. Remove the Daytime Running Lights (DRL) sensor wiring harness clip (1) from the HVAC module assembly.
18. Disconnect the IP lamp dimmer switch electrical connector (2).
19. Remove the wiring harness clips (3) from the HVAC module assembly bracket.
20. Disconnect the vacuum hose (4) from the vacuum tank.






21. Disconnect the blower motor resistor electrical connector.
22. Disconnect the blower motor electrical connector.






23. Disconnect the temperature actuator electrical connector.






24. Remove the HVAC module assembly.

INSTALLATION PROCEDURE






1. Position the HVAC module assembly to the vehicle.






2. Connect the temperature actuator electrical connector.






3. Connect the blower motor resistor electrical connector.
4. Connect the blower motor electrical connector.






5. Install the wiring harness clips (3) to the HVAC module assembly bracket.
6. Install the Daytime Running Lights (DRL) sensor wiring harness clip (1) from the HVAC module assembly.
7. Connect the IP lamp dimmer switch electrical connector (2).
8. Install the vacuum hose (4) to the vacuum tank.






9. Install the cross vehicle beam (tie bar). Refer to Instrument Panel Tie Bar Replacement Service and Repair.
10. Install the floor air duct to the HVAC module assembly.
11. Install the air distribution duct. Refer to Air Distributor Duct Replacement Service and Repair.
12. Install the Instrument Panel (IP) carrier. Refer to Instrument Panel Trim Pad Replacement Service and Repair.
13. Raise the vehicle.

Notice: 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.

14. Install the nut for the HVAC module assembly bracket.

Tighten
Tighten the bracket nut to 10 Nm (88 lb in).

15. Install the heater case plate and the seals for the heater pipes.
16. Install the nuts holding the heater case plate for the heater pipes.
17. Install the heater case plate and seal for the evaporator block.
18. Install the nuts holding the heater case plate for the evaporator block.

Tighten
Tighten the heater case plates nuts to 10 Nm (88 lb in).






19. Install the drain tube elbow to the evaporator block heater case plate.
20. Install the evaporator hose to the evaporator. Refer to Air Conditioning Evaporator Hose Assembly Replacement Service and Repair.
21. Install the heater hoses to the heater core. Refer to Heater Hose Replacement Service and Repair.
22. Lower the vehicle.
23. Fill the engine cooling system. Refer to Draining and Filling Cooling System Service and Repair.
24. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging Service and Repair.
25. Leak test the fittings of the component using the J 39400-A.