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 assembly.




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

NOTE: Refer to Fastener Notice in Service Precautions.

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

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 assembly.




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




12. Connect the evaporator hose connection to the evaporator.

IMPORTANT:
- Inspect the seal washers for damage before reinstalling the A/C lines and hoses.
- If any damage is noted during inspection, the suspect seal must be replaced.
- Flat washer type seals do not require lubrication.

13. Install the evaporator hose nut.

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

14. Recharge the A/C system.
15. Test the A/C system for leaks using the J 39400-A.
16. Refill the engine coolant.