Housing Assembly HVAC: Service and Repair

Air Conditioning and Heater Module Assembly Replacement

Tools Required

J 39400-A Halogen Leak Detector
SA9111E Hose Clamp Pliers

Removal Procedure

1. Disable the frontal and curtain air bags.
2. Recover the refrigerant.
3. Drain engine coolant.





4. Remove suction line at TXV and install protective cap to suction line.





Important: Place protective cover over A/C lines and TXV to prevent contamination of A/C system.

5. Remove liquid line at TXV and install protective cap to liquid line and TXV.





6. Disconnect TXV temperature sensor connector.





7. Reposition the heater inlet hose at the heater core using SA9111E .
8. Remove heater hose at heater core outlet.





9 Reposition the heater outlet hose at the heater core using SA9111E.
10. Remove heater hose at heater core inlet.
11. Plug heater core pipes with clean towels to prevent spillage when removing module.
12. Remove the instrument panel (I/P) retainer. Refer to Instrument Panel Retainer Replacementin Instrument Panel, Gauge., and Console.
13. Remove the shift control bracket. Refer to Transmission Shift Control Bracket Replacement in Manual Transmission -- Getrag 5, Transmission Control Bracket Replacementin Automatic Transaxle -- AF33-5, or Transmission Control Bracket Replacement in Automatic Transmission -- VT25-E





14. Remove front rear duct by sliding forward on heater duct then up at rear and then rearward.





15. Remove auxiliary duct assembly.





16. Disconnect I/P harness at blower motor connector.
17. Disconnect I/P harness at blower motor resistor connector.
18. Disconnect I/P harness at HVAC module connector.





19. Remove defroster duct to HVAC module nuts and defroster duct.
20. Disconnect I/P wire harness clips from HVAC module.





21. Remove left HVAC module to cross car beam stamped metal L-type bracket from HVAC module and cross car beam.





22. Remove remaining HVAC module to cross car beam and front of dash fasteners and remove HVAC module.

Installation Procedure

Important: Make sure seals on HVAC module are flush and even as the meet their mating surfaces. This will reduce the chance of leaks and insure proper fit.

1. Check front of dash seal for proper alignment.
2. Check seal mating surfaces to insure there are no obstructions.

Important: Make sure center "molded in case" HVAC to cross car beam bracket is forward of cross car beam down flange.

3. Loose hang HVAC module from cross car beam.





Important: New front of dash seal nuts must be used to prevent leaks.

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.

4. Install front of dash to HVAC module seal nuts, draw module to FOD evenly with nuts and tighten.

Tighten
Tighten the nuts to 8 N.m (71 lb in).





5. Push up on HVAC module at blower motor area while tightening right side HVAC module to cross car beam fasteners (to seat screen assembly/fresh air seal).

Tighten
Tighten the fasteners to 8 N.m (71 lb in).

6. Install the left HVAC module to cross car beam stamped metal L-type bracket to HVAC module and cross car beam and tighten remaining module attachment fasteners.

Tighten
Tighten the fasteners to 8 N.m (71 lb in).

7. Connect I/P wire harness clips to HVAC module.





8. Install defroster duct to HVAC module nuts and defroster duct.

Tighten
Tighten the nuts to 2.5 N.m (22 lb in).





9. Connect I/P harness to blower motor connector.
10. Connect I/P harness to blower motor resistor connector.
11. Connect I/P harness to HVAC module connector.





12. Install auxiliary duct assembly.





13. Install front rear duct by sliding forward on heater duct then down and rearward over rear duct.
14. Install the shift control bracket. Refer to Transmission Shift Control Bracket Replacement in Manual Transmission -- Getrag 5, Transmission Control Bracket Replacementin Automatic Transaxle -- AF33-5, or Transmission Control Bracket Replacement in Automatic Transmission -- VT25-E
15. Install the I/P retainer.





16. Install heater inlet hose to heater core inlet.
17. Position the clamp at 9 o'clock using SA9111E.





18. Install heater outlet hose to heater core outlet.
19. Position the clamp at 9 o'clock position using SA9111E.





20. Insure mating surfaces are clean and free of debris, and install a new seal washer to the liquid line.
21. Install the liquid line and nut to the thermal expansion valve (TXV).

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





22. Insure mating surfaces are clean and free of debris, and install a new seal washer to the suction hose.
23. Install the suction hose and nut to the thermal expansion valve (TXV).

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

24. Enable the frontal and curtain air bags.
25. Fill the coolant.
26. Evacuate and charge the refrigerant system.
27. Leak test the fittings using the J 39400-A.