Air Conditioning and Heater Module Assembly

Air Conditioning and Heater Module Assembly Removal and Installation

Special Tools

* J 38185 - Hose Clamp Pliers

* J 39400-A - Halogen Leak Detector

* J 45689 - A/C Quick Joint Tool

Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Belt Driven Compressor) Refrigerant Recovery and Recharging (Belt Driven Compressor).

2. Remove the battery. Refer to Battery Replacement Removal and Replacement.

3. Drain the coolant. Refer to Cooling System Draining and Filling (Static Fill LFW or LFX) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Static Fill LSA) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716 LFW or LFX) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (GE 47716 LSA) Cooling System Draining and Filling (GE 47716).




4. Using the J 38185 - hose clamp pliers disconnect the heater inlet hose (1).




5. Using the J 38185 - hose clamp pliers disconnect the heater outlet hose (1).

6. Disconnect both A/C lines at the cowl.





Note: The body of the tool should be parallel to the A/C line.

7. Using the J 45689 - A/C quick joint tool (1) insert the probe end into the two small openings of the plastic quick joint.

8. Remove both quick joint clamps.

9. Disconnect both A/C lines.




10. Remove the I/P Carrier. Refer to Instrument Panel Carrier Replacement (Left Hand Drive) Instrument Panel Carrier Replacement (Left Hand Drive)Instrument Panel Carrier Replacement (Right Hand Drive) Instrument Panel Carrier Replacement (Right Hand Drive).

11. Remove the air inlet assembly.

12. Disconnect the HVAC module electrical connector.

13. Disconnect the HVAC module drain tube (2) from the floor.




14. Press the tab and release the left rear duct from the HVAC module.




15. Disconnect the left rear heater duct from the HVAC module.




16. Press the tab and release the right rear duct from the HVAC module.




17. Disconnect the right rear heater ducts from the HVAC module.




18. Remove the lower left HVAC module mounting nut (1).




19. Remove the upper left HVAC module mounting nut (1).

20. Remove the HVAC module from the vehicle.




21. Remove the foam from the A/C lines.

22. Remove the foam from around the heater pipes.

Installation Procedure




1. Install the thick foam packing (1) on the heater core pipes.

2. Install the thin foam packing (2) on the heater core pipes.




3. Install the thick foam packing (1) on the A/C lines.

4. Install the thin foam packing (2) on the A/C lines.

5. Install the HVAC module into the vehicle.

Caution: Refer to Fastener Caution Fastener Caution.

6. Install the upper left HVAC module mounting nut (1) and tighten to 9 Nm (80 lb in).




7. Install the lower left HVAC module mounting nut (1) and tighten to 9 Nm (80 lb in).

8. Connect the rear heater ducts to the HVAC module.

9. Connect the drain tube to the bottom of the HVAC module.




10. Connect the drain tube (2) to the floor.

11. Connect the HVAC electrical connector.

12. Install the air inlet assembly.




13. Lubricate the O-rings of the A/C line with refrigerant oil before connecting the A/C lines. Refer to Air Conditioning O-Ring Seal Replacement Service and Repair.




14. Install the A/C line and A/C line quick connect line clamp (1) to the evaporator.





Note: Press the A/C line quick connect line clamp together until you hear it engage.

15. Engage the clamp.




16. Install the A/C line and A/C line quick connect line clamp (1) to the evaporator.





Note: Press the A/C line quick connect line clamp together until you hear it engage.

17. Engage the clamp.




18. Connect the heater inlet hose (1) using J 38185 - hose clamp pliers.




19. Connect the heater outlet hose (1) using J 38185 - hose clamp pliers.

20. Install the I/P carrier. Refer to Instrument Panel Carrier Replacement (Left Hand Drive) Instrument Panel Carrier Replacement (Left Hand Drive)Instrument Panel Carrier Replacement (Right Hand Drive) Instrument Panel Carrier Replacement (Right Hand Drive).

21. Install the battery. Refer to Battery Replacement Removal and Replacement.

22. Fill the coolant. Refer to Cooling System Draining and Filling (Static Fill LFW or LFX) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Static Fill LSA) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716 LFW or LFX) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (GE 47716 LSA) Cooling System Draining and Filling (GE 47716).

23. Evacuate and recharge the AC system. Refer to Refrigerant Recovery and Recharging (Belt Driven Compressor) Refrigerant Recovery and Recharging (Belt Driven Compressor).

24. Leak test the fittings of the component using J 39400-A - halogen leak detector.