HVAC System - Manual

TOOLS REQUIRED
- J 39400-A Halogen Leak Detector
- J 38185 Hose Clamp Pliers

REMOVAL PROCEDURE
1. Disconnect the battery negative cable.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Recover the refrigerant.
3. Drain the cooling system.
4. Remove the cross vehicle brace.




5. Remove the accumulator tube to evaporator core block fitting bolt.
6. Disconnect the accumulator tube from the evaporator.
7. Disconnect the evaporator tube from the evaporator.
8. Remove the O-rings seals and discard.




9. Use J 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
10. Disconnect the inlet and outlet heater hose from the heater core.
11. Remove the IP lower trim panel.




12. Remove the retaining screw (1) from the panel air duct.
13. Remove the retaining bolts from the panel air duct.
14. Remove the panel air duct from the cross vehicle beam.




15. Remove the retaining bolts from the right air duct.
16. Remove the right air duct from the cross vehicle beam.
17. Remove the steering column.
18. Disconnect the left side fuse block from the cross vehicle beam.
19. Remove the passenger knee bolster bracket.
20. Position the body control module away from the cross vehicle beam.
21. Disconnect any ground wires, as necessary.
22. Remove the brake pedal.
23. Remove the 3 bolts from the brake pedal bracket to cross vehicle beam.
24. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.




25. Remove the bolts from the HVAC module center support.
26. Remove the bracket from the HVAC module center support.
27. Reposition the vacuum harness.




28. Remove the bracket bolts from the HVAC module upper support.




29. Remove the bolts from the right and left side of the cross vehicle beam.




30. Remove the cross vehicle beam.
31. Disconnect the vacuum hoses from the HVAC control module.
32. Disconnect the electrical connectors from the HVAC control module.




33. Remove the evaporator drain elbow.




34. Remove the nuts which secure the HVAC control module to the dash.
35. Remove the HVAC control module:
35.1. Pull the HVAC control module rearward to disengage the mounting studs from the dash panel.
35.2. Position aside the dash insulator pad from the recirculation opening of the HVAC control module.
35.3. Roll the HVAC control module downward and rearward to disconnect the heater core outlet cover from the rear floor air outlet duct.
35.4. Remove the HVAC control module.




36. Remove and discard all of the seals (1,2,3) from the outer HVAC control module.

INSTALLATION PROCEDURE




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

IMPORTANT: When installing the HVAC control module, ensure that the dash insulator pad cut-outs and the HVAC seals, studs, and drain align and seal properly to the dash panel.

2.1. Align the heater core outlet cover to the rear floor air outlet duct.
2.2. Roll the HVAC control module forward and upward and align the dash insulator pad to the recirculation opening of the HVAC control module.
2.3. Align the mounting studs and the drain on the HVAC control module to seat against the dash panel.




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

NOTE: Refer to Fastener Notice in Service Precautions.

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




4. Install the evaporator drain elbow.
5. Connect the vacuum hoses to the HVAC control module.
6. Connect the electrical connectors to the HVAC control module.




7. Install the cross vehicle beam to the vehicle.




8. Install the bolts to the right and left side of the cross vehicle beam.
9. Tighten the bolts to the right and left side of the cross vehicle beam in sequence.

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




10. Install the bracket bolts to the HVAC module upper support.

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

11. Install the passenger knee bolster bracket.




12. Install the bracket to the HVAC module center support.
13. Install the bolts to the HVAC module center support.
14. Reposition the vacuum harness to the original position.
15. Tighten the bolts in sequence as shown.

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

16. Reposition the IP wiring harness on to the cross vehicle beam and secure the retaining clips.
17. Install the 3 bolts through the brake pedal bracket to the cross vehicle beam.

Tighten
Tighten the bolts to 50 N.m (37 lb ft).

18. Install the brake pedal.
19. Connect all disconnected ground wires.
20. Install the body control module.
21. Install the left side fuse block to the cross vehicle beam.
22. Install the steering column.




23. Install the right air duct to the cross vehicle beam.
24. Install the right air duct bolts.

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




25. Install the panel air duct to the cross vehicle beam.
26. Install the panel air duct screw (1).

Tighten
Tighten the screw to 1.8 N.m (16 lb in).

27. Install the panel air duct bolts.

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

28. Install the IP lower trim panel.




29. Connect the inlet and outlet heater hose to the heater core.

IMPORTANT: Reposition the heater core hose clamps in the indicated location.

30. Use J 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.
31. Install new O-rings seals on the evaporator tube and accumulator tube.




32. Connect the evaporator tube to the evaporator.
33. Connect the accumulator tube to the evaporator.
34. Install the accumulator tube to evaporator core block fitting bolt.

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

35. Install the cross vehicle brace.
36. Fill the cooling system.
37. Evacuate and recharge the A/C system.
38. Connect the battery negative cable.
39. Leak test the fittings of the component using J 39400-A.