Auxiliary HVAC Module Removal and Installation

Auxiliary HVAC Module Removal and Installation

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant.
2. Remove the left rear quarter trim panel.
3. Drain the cooling system.
4. Raise and support the vehicle.
5. Remove the level ride air compressor.






6. Remove the auxiliary A/C line block fitting bolt.
7. Disconnect the A/C line block fitting.
8. Remove and discard the sealing washers.

Important: Cap or tape the open A/C refrigerant lines immediately to prevent system contamination.

9. Cap or tape the A/C lines.






10. Disconnect the auxiliary heater hoses from the heater core pipes.
11. Lower the vehicle.






12. Remove the air distribution duct mounting bolts.
13. Remove the air distribution duct mounting retainer.
14. Disconnect the air distribution duct from the HVAC module.
15. Disconnect the auxiliary blower motor electrical connector.
16. Disconnect the auxiliary blower motor resistor electrical connector.
17. Disconnect the auxiliary temperature actuator electrical connector.






18. Remove the HVAC module assembly mounting bolts and nut.
19. Disconnect the left PSD module from the mounting bracket and reposition aside.
20. Remove the HVAC module assembly from the vehicle.
21. Remove and discard the HVAC module assembly to body seals.

Installation Procedure

1. Install new HVAC module assembly to body seals.






2. Install the HVAC module assembly to 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.

3. Install the HVAC module assembly mounting bolts and the nut.

Tighten
Tighten the bolts and the nut to 10 Nm (89 lb in).

4. Connect the left PSD module to the mounting bracket.






5. Connect the auxiliary temperature actuator electrical connector.
6. Connect the electrical connector to the auxiliary blower motor resistor.
7. Connect the auxiliary blower motor electrical connector.
8. Connect the auxiliary air distribution duct to the HVAC module assembly.
9. Install the auxiliary air distribution duct mounting bolts.

Tighten
Tighten the bolts to 10 Nm (89 lb in).

10. Install the air distribution duct mounting retainer.
11. Raise and support the vehicle.






12. Connect the auxiliary heater hoses to the heater core pipes.
13. Remove the cap or tape from the A/C lines.
14. Install the new sealing washers onto the A/C line.






15. Install the auxiliary A/C line block fitting bolt.

Tighten
Tighten the bolt to 20 Nm (15 lb ft).

16. Install the level ride air compressor.
17. Lower the vehicle.
18. Fill the cooling system.
19. Evacuate and recharge the A/C system.
20. Leak test the fittings of the component using J 39400-A.
21. Install the left rear quarter trim panel.