Housing Assembly HVAC: Service and Repair

Removal Procedure




1. Remove the instrument panel. Refer to IP Carrier Replacement in Instrument Panel, Gauges and Console.
2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
3. Remove the blower motor resistor. Refer to Blower Motor Resistor Replacement.

IMPORTANT: Mark and use the same mounting bolt (located behind the A/C evaporator and blower module) for the heater assembly during the installation process. Other mounting bolts are longer and will obstruct the operation of the temperature door.




4. Remove the heat/vent module mounting bolt through the blower motor resistor or service access cover opening.
5. On vehicles with A/C only, remove the right wheel house panel. Refer to Wheelhouse Panel Replacement in Body Front End.
6. On vehicles with A/C only, raise and support vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. On vehicles with A/C only, remove the front right tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
8. Remove the 2 lower heat/vent module mounting nuts.
9. Remove the bottom right heat/vent module mounting bolt from inside the vehicle.




10. On vehicles with A/C only, lower the vehicle.
On vehicles with a 2.2L engine only, remove the engine wiring harness bracket located at the rear of the intake manifold. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical - 2.2L.

11. Remove the heat/vent module mounting bolt located at the lower left side of the heater core to heater hose connection.
12. Remove the heat/vent module mounting nut located at the lower right side of the heater core to heater connection.
13. Disconnect all of the electrical connectors from the heat/vent module.
14. Disconnect all of the vacuum lines from the heater assembly.
15. Disconnect the heater hoses from the heater core.
16. Remove the heat/vent module from the vehicle.

Installation Procedure




1. If replacing the heat/vent module, transfer the components from the old heat/vent module as necessary.

IMPORTANT: Before installing the heat/vent module to the vehicle, ensure that the heat/vent module mounting studs are located in the proper positions.

2. Install the heat/vent module to the vehicle.
3. Connect the heater hoses to the heater core.
4. Connect all of the vacuum lines to the heater assembly.
5. Connect all of the electrical connectors to the heat/vent module.
6. Install the bottom right heat/vent module mounting bolt from inside the vehicle approximately halfway into the threads.
7. On vehicles with A/C only, raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.




8. Install the heater/vent module mounting nuts.

Tighten
Tighten the heat/vent module mounting nuts to 4.5 N.m (22 lb in).

On vehicles with A/C only, install the right front tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

9. On vehicles with A/C only, lower the vehicle.
10. Install the bottom right heat/vent module mounting bolt from inside the vehicle.

Tighten
Tighten the heat/vent module mounting bolt to 4.5 N.m (22 lb in).

11. On vehicles with A/C only, install the right wheel house panel. Refer to Wheelhouse Panel Replacement in Body Front End.




12. Install the heat/vent module mounting nut located at the lower right side of the heater core to heater connection.

Tighten
Tighten the heat/vent module mounting nut to 4.5 N.m (22 lb in).

13. Install the heat/vent module mounting bolt located at the lower left side of the heater core to heater hose connection.

Tighten
Tighten the heat/vent module mounting bolt to 4.5 N.m (22 lb in).




14. On vehicles with the 2.2L engine only, install the engine wiring harness bracket located at the rear of the intake manifold. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical - 2.2L.

IMPORTANT: Mark and use the same mounting bolt (located behind the A/C evaporator and blower module) for the heater assembly during the installation process. Other mounting bolts are longer and will obstruct the operation of the temperature door.

15. Install the heat/vent module mounting bolt through the blower motor resistor or service access cover opening.

Tighten
Tighten the heat/vent module mounting bolt to 4.5 N.m (22 lb in).

16. Install the blower motor resistor. Refer to Blower Motor Resistor Replacement.
17. Refill the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
18. Install the instrument panel. Refer to IP Carrier Replacement in Instrument Panel, Gauges and Console.