Housing Assembly HVAC: Service and Repair

HVAC Module Assembly Replacement

Tools Required

* J 39400-A Halogen Leak Detector
* J 38185 Hose Clamp Pliers

Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Disconnect the battery negative cable.
3. Remove the air cleaner assembly.
4. Remove the fuel injector sight shield.
5. Drain the cooling system. Refer to Draining and Filling Cooling System (GE 47716 Fill) Draining and Filling Cooling System (L26 Static Fill) Draining and Filling Cooling System (LY7 Static Fill).
6. Remove the instrument panel (I/P) trim pad.
7. Remove the bolt from the accessory wiring junction block.
8. Disengage the junction block tabs from the passenger knee bolster. Remove the junction block from the knee bolster.
9. Remove the brake pedal nut and bolt.
10. Remove the brake pedal brace bolts from the I/P carrier cross car beam.
11. Disconnect any ground wires, as necessary.
12. Reposition the I/P wiring harness out of the way.




13. Remove the bracket bolt from the HVAC module assembly right support (2).
14. Remove the bracket bolts from the HVAC module assembly lower support (1).




15. Remove the bracket bolts from the HVAC module assembly upper support.
16. Remove the right and the left I/P carrier bolts.
17. Remove the I/P carrier.




18. Remove the nut (1) that secures the evaporator tube to the thermostatic expansion valve (TXV).
19. Disconnect the evaporator tube from the TXV.
20. Remove the seal washers and discard.




21. Use J 38185 in order to position aside the inlet heater hose clamp at the heater core.
22. Use J 38185 in order to position aside the outlet heater hose clamp at the heater core.
23. Disconnect the inlet heater hose from the heater core.
24. Disconnect the outlet heater hose from the heater core.
25. Disconnect the electrical connectors from the HVAC module assembly.




26. Remove the evaporator drain elbow.




27. Remove the nuts which secure the HVAC module assembly to the dash.
28. Remove the HVAC module assembly.




29. Remove all of the seals (1, 2, 3) from the outer HVAC module assembly.

Installation Procedure




1. Install new seals (1, 2, 3) to the outer HVAC module assembly.
2. Install the HVAC module assembly to the vehicle.






Notice: Refer to Fastener Notice.

3. Install the nuts which secure the HVAC module assembly to the dash.

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




4. Install the evaporator drain elbow.
5. Connect the electrical connectors to the HVAC module assembly.
6. Install the I/P carrier to the vehicle. Align the I/P carrier to the HVAC module assembly and the hinge pillars.
7. Install the bolts to the right and the left I/P carrier.

Tighten the bolts to 25 N.m (18 lb ft).




8. Install the bolts to the HVAC module assembly upper support bracket.

Tighten the bolts to 4 N.m (36 lb in).




9. Install the bolts to the HVAC module assembly lower support bracket (1).

Tighten the bolts to 4 N.m (36 lb in).

10. Install the bolt to the HVAC module assembly right support bracket (2).

Tighten the bolt to 4 N.m (36 lb in).

11. Position the I/P wiring harness to the original position.
12. Connect any disconnected ground wires.
13. Install the brake pedal brace bolts to the I/P carrier.
14. Position the brake pedal to the brake pedal brace.
15. Install the brake pedal bolt and nut.
16. Seat the bottom junction block tabs and snap the top of the junction block to the passenger knee bolster.
17. Install the junction block bolt.

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

18. Install the I/P trim pad.




19. Connect the inlet heater hose to the heater core.
20. Connect the outlet heater hose to the heater core.
21. Use J 38185 in order to reposition the inlet heater hose clamp to the heater core.
22. Use J 38185 in order to reposition the outlet heater hose clamp to the heater core.
23. Install the fuel injector sight shield.
24. Fill the cooling system. Refer to Draining and Filling Cooling System (GE 47716 Fill) Draining and Filling Cooling System (L26 Static Fill) Draining and Filling Cooling System (LY7 Static Fill).
25. Install new sealing washers on the evaporator tube.




26. Connect the evaporator tube to the TXV.
27. Install the evaporator tube to the TXV block fitting nut (1).

Tighten the nut to 17 N.m (12.5 lb ft).

28. Install the air cleaner assembly.
29. Connect the battery negative cable.
30. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
31. Leak test the fittings of the component using J 39400-A.