Housing Assembly HVAC: Service and Repair

HVAC MODULE ASSEMBLY REPLACEMENT

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

REMOVAL PROCEDURE




1. Recover the refrigerant.
2. Drain the coolant.
3. Remove the evaporator hose nut.
4. Disconnect the evaporator hose connection at the evaporator.




5. Remove the heater hoses from the heater core using the J 38185.
6. Plug the heater core and evaporator openings to prevent leaking into the vehicle when removing module assembly.
7. Pinch off the hoses in order to prevent leaking.




8. Remove the IP carrier.
9. Remove the defroster duct retaining screws (1, 2).
10. Remove the defroster duct nut (3).
11. Remove the defroster duct.
12. Remove the air distributor duct.




13. Disconnect the blower control module (1) connection.
14. Disconnect the IP harness to A/C module (2) electrical connector




15. Remove the HVAC module retaining nuts (1-5).
16. Remove the HVAC module.

INSTALLATION PROCEDURE




1. Install the HVAC module.

NOTE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: the illustration for the HVAC module fastener torque sequence.

2. Install the HVAC module nuts to the dash (1-5).

Tighten
Tighten the nuts to 9 N.m (80 lb in).




3. Connect the blower control module (1) connection.
4. Connect the IP to A/C module connector (2).




5. Install the defroster duct.
6. install the mounting screws (1,2).

Tighten
Tighten the screws to 1.4 N.m (12 lb in).

7. Install the defroster duct mounting nut (3) to the front of dash.

Tighten
Tighten the nut to 9 N.m (80 lb in).

8. Install the air distributor duct.
9. Install the air distributor duct screws.

Tighten
Tighten the screws to 1.4 N.m (12 lb in).

10. Install the IP carrier.




11. Install the heater hoses to the heater core using the J 38185.




12. Install new sealing washers.
13. Connect the evaporator hose connection to the evaporator.
14. Install the evaporator hose nut.

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

15. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
16. Test the A/C system for leaks using the J 39400-A. Refer to Leak Testing.
17. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.