HVAC Module Assembly Replacement
TOOLS REQUIREDJ 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the left wiper arm linkage nuts. Reposition the left wiper arm linkage for access.
IMPORTANT: The defroster door must be closed to allow clearance during defroster duct removal.
4. Set the HVAC controls in the vent setting to close the defroster door.
5. Remove the blower motor.
6. Disconnect the electrical connector from the blower motor resister.
7. Disconnect the electrical connector from the evaporator temperature sensor.
8. Disconnect all of the HVAC electrical actuator connectors.
9. Remove the cross vehicle beam.
10. Remove the evaporator outlet tube nut.
11. Disconnect the evaporator outlet tube.
12. Disconnect the evaporator inlet tube.
13. Reposition the inlet heater hose clamp.
14. Disconnect the inlet heater hose from the heater core.
15. Reposition the outlet heater hose clamp.
16. Disconnect the outlet heater hose from the heater core.
17. Remove the HVAC module to brake pedal bracket nuts.
18. Remove the HVAC module assembly from the cowl.
INSTALLATION PROCEDURE
IMPORTANT: Ensure proper alignment of the HVAC module assembly and HVAC module drain through the cowl.
1. Install the HVAC module assembly to the cowl.
2. Install the HVAC module assembly to brake pedal bracket nuts.
Do not tighten the HVAC module assembly nuts at this time.
3. Connect the outlet heater hose to the heater core.
4. Reposition the outlet heater hose clamp.
5. Connect the inlet heater hose to the heater core.
6. Reposition the inlet heater hose clamp.
7. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant lines and the TXV.
8. Lightly coat the new sealing washers with mineral base 525 viscosity refrigerant oil.
IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new sealing washers to enter the refrigerant system.
9. Install the new sealing washers.
10. Connect the evaporator inlet tube to the evaporator outlet tube.
11. Connect the evaporator inlet and outlet tubes to the TXV.
NOTE: Refer to Fastener Notice in Service Precautions.
12. Install the evaporator outlet tube nut at the TXV.
Tighten
Tighten the nut to 16 N.m (12 lb ft).
13. Install the cross vehicle beam.
14. Connect all of the HVAC electrical actuator connectors.
15. Connect the electrical connector to the evaporator temperature sensor.
16. Connect the electrical connector to the blower motor resister.
17. Install the blower motor.
18. Install the HVAC module assembly to brake pedal bracket nuts.
Tighten
Tighten the nuts to 10 N.m (89 lb in).
19. Install the left wiper arm linkage.
20. Install the left wiper arm linkage nuts.
Tighten
Tighten the nuts to 5 N.m (44 lb in).
21. Fill the coolant system. Refer to Draining and Filling Cooling System in Cooling System.
22. Evacuate and recharge the refrigerant. Refer to Refrigerant Recovery and Recharging.
23. Leak test the fittings of the component using J 39400-A.