HVAC Module Assembly Replacement

HVAC MODULE ASSEMBLY REPLACEMENT

TOOLS REQUIRED
J 39400-A Halogen Leak Detector

REMOVAL PROCEDURE
1. Recover the refrigerant from the A/C system. 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.
4. Set the HVAC controls in the vent setting to close the defroster door.

IMPORTANT: The defroster door must be closed to allow clearance during defroster duct removal.

5. Remove the blower motor.




6. Disconnect the electrical connector from the blower motor resistor.




7. Disconnect the electrical connector from the evaporator temperature sensor.
8. Disconnect all of the HVAC actuator electrical connectors.
9. Remove the instrument panel (I/P) carrier.




10. Remove the evaporator outlet tube nut.
11. Disconnect the evaporator outlet tube and evaporator inlet tube from the thermal expansion valve (TXV).
12. Remove and discard the sealing washers.
13. Remove the heater inlet hose from the heater core.
14. Remove the heater outlet hose from the heater core.




15. Remove the HVAC module to dash panel sound barrier nuts.
16. Remove the HVAC module assembly from the cowl.

INSTALLATION PROCEDURE

IMPORTANT: Ensure proper alignment of the HVAC module assembly and HVAC module drain tube through the cowl.

1. Install the HVAC module assembly to the cowl.




2. Install the HVAC module assembly to dash panel sound barrier nuts.Do not tighten the HVAC module assembly nuts at this time.
3. Install the heater outlet hose to the heater core.
4. Install the heater inlet hose to the heater core.
5. Install new sealing washers onto the evaporator inlet and outlet tubes.
6. Connect the evaporator inlet tube to the evaporator outlet tube.
7. Connect the evaporator inlet and outlet tubes to the TXV.




8. Install the evaporator outlet tube nut at the TXV.

Tighten the nut to 16 N.m (12 lb ft).

NOTE: Refer to Fastener Notice in Service Precautions.

9. Install the I/P carrier.
10. Connect all of the HVAC actuator electrical connectors.




11. Connect the electrical connector to the evaporator temperature sensor.




12. Connect the electrical connector to the blower motor resistor.
13. Install the blower motor.




14. Tighten the HVAC module assembly to dash panel sound barrier nuts.

Tighten the nuts to 10 N.m (89 lb in).

15. Install the left wiper arm linkage.
16. Install the left wiper arm linkage nuts.

Tighten the nuts to 5 N.m (44 lb in).

17. Fill the coolant system. Refer to Draining and Filling Cooling System in Cooling System.
18. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
19. Leak test the fittings of the component using the J 39400-A.