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. Refer to Refrigerant Recovery and Recharging.
2. Drain the coolant.




3. Remove the evaporator hose nut.
4. Remove the evaporator hose from the evaporator.
5. Remove and discard the sealing washers from the evaporator hose.




6. Remove the heater hoses from the heater core using the J 38185.
7. Plug the heater core and evaporator openings to prevent leaking into the vehicle when removing the HVAC module.
8. Pinch off the hoses in order to prevent leaking.
9. Remove the instrument panel (I/P) assembly.




10. Remove the defroster duct retaining screws (1, 2).
11. Remove the defroster duct nut (3).
12. Remove the defroster duct.
13. Remove the air distributor duct.




14. Disconnect the blower control module (1) connector.
15. Disconnect the I/P harness to HVAC module (2) electrical connector.




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

INSTALLATION PROCEDURE




1. Install the HVAC module.

NOTE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: Refer to 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 I/P to HVAC 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 I/P assembly.




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




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

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

15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
16. Leak test the fittings of the component using the J 39400-A.
17. Fill the engine coolant.