Except Crew Cab

HVAC MODULE ASSEMBLY REPLACEMENT (W/ AIR CONDITIONING)

TOOLS REQUIRED
- J 43181 Heater Line Quick Connect Release Tool
- J 39400-A Halogen Leak Detector

REMOVAL PROCEDURE
1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
3. Remove the I/P carrier.




4. Release the heater hose clamps using J 43181.
5. Disconnect the heater hose quick connects (2) and (3) from the heater core.




6. Remove the retaining nut from the TXV stud.
7. Remove the evaporator tube and suction hose from the TXV.
8. Disconnect all of the electrical connectors to the HVAC module assembly.
9. Remove the HVAC module retaining nuts from the cowl.
10. Remove the HVAC module assembly.

INSTALLATION PROCEDURE
1. Install the HVAC module assembly.
2. Install the HVAC module retaining nuts from the cowl.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Tighten the HVAC module retaining nuts.

Tighten
Tighten the nut to 4.5 N.m (40 lb in).




4. If replacing the HVAC module assembly (8), transfer the components from the old HVAC module assembly as necessary.
5. Install the HVAC module assembly (8).
6. Connect all of the electrical connectors to the HVAC module assembly.




7. Connect the heater hose quick connects (2) and (3) to the heater core.
8. Install the evaporator tube and suction hose to the TXV.
9. Install the retaining nut to the TXV stud.

NOTE: Refer to Fastener Notice in Service Precautions.

10. Tighten the retaining nut.

Tighten
Tighten the nut to 4.5 N.m (40 lb in).

11. Install the I/P carrier.
12. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
13. Leak test the fittings of the components using the J 39400-A.
14. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.