Housing Assembly HVAC: Service and Repair

HVAC MODULE ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE

TOOLS REQUIRED
^ J 39500-B Air Conditioning Refrigerant Recovery, Recycling and Recharging (ACR4) System
^ J 38185 Hose Clamp Pliers




1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
2. Remove the evaporator hose nut.
3. Disconnect the evaporator hose connection at the evaporator.




4. Remove the heater hoses from the heater core using the J 38185.
5. Plug the heater core and evaporator openings to prevent leaking into the vehicle when removing module assembly.
6. Pinch off the hoses in order to prevent leaking.




7. Remove the IP assembly.
8. Remove the defroster duct retaining screws (1,2).
9. Remove the defroster duct nut (3).
10. Remove the defroster duct.
11. Remove the air distributor duct screws and duct.




12. Disconnect the blower control module (1) connection.
13. Disconnect the I/P to HVAC module (2) connection.




14. Remove the HVAC module retaining nuts (1-5).
15. Remove the HVAC module.

INSTALLATION PROCEDURE

TOOLS REQUIRED
J 39400-A Electronic Halogen Leak Detector




1. Install the HVAC module.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the HVAC module nuts to the dash (1-5).

Tighten
Tighten the nuts to 9 N.m (80 lb in).




3. Connect the blower control module (1) connection.
4. Connect the I/P to HVAC module connector (2).




5. Install the defroster duct and the module mounting screws (1,2).

Tighten
Tighten the screws to 1.4 N.m (12 lb in).

6. Install the defroster duct mounting nut (3) to the front of dash.

Tighten
Tighten the nut to 9 N.m (80 lb in).

7. Install the air distributor duct and screws.

Tighten
Tighten the screws to 1.4 N.m (12 lb in).

8. Install the IP assembly.




9. Install the heater hoses to the heater core using the J 38185.

IMPORTANT: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.

Flat washer type seals do not require lubrication.




10. Connect the evaporator hose connection to the evaporator.
11. Install the evaporator hose nut.

Tighten
Tighten the nut to 20 N.m (15 lb ft).

12. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
13. Test the A/C system for leaks using the J 39400-A. Refer to Leak Testing
14. Refill the engine coolant.