HVAC Module Installation
HVAC MODULEIMPORTANT: Make sure seals on HVAC module are flush and even as the meet their mating surfaces. This will reduce the chance 0 leaks and insure proper fit.
1. Check flout of dash seal for proper alignment.
2. Check seal mating surfaces to insure there are no obstructions.
3. Loose hang HVAC module from cross ear beam.
NOTE: New front of dash seal nuts must be used to prevent leaks.
IMPORTANT: Make sure center "molded in case" HVAC to cross car beam bracket is forward of cross car beam down flange.
4. Install front of dash to HVAC module seal nuts, draw module to FOD evenly with nuts and tighten.
Torque:
Front of Dash to HVAC Module Seal Nuts: 8 N.m (70 in-lbs)
5. Push up on HVAC module at blower motor area while tightening right side HVAC module to cross car beam fasteners (to seat screen assembly/fresh air seal).
6. Install left HVAC module to cross car beam stamped metal L-Type bracket to HVAC module and cross car beam and tighten remaining module attachment fasteners.
Torque:
HVAC Module to Cross Car Beam Stamped Metal L-Type Bracket to Beam: 8 N.m (70 in-lbs)
7. Connect I/P wire harness clips to HVAC module.
8. Install defroster duct to HVAC module nuts and defroster duct.
Torque:
Defroster Duct Nuts: 2.5 N.m (22 in-lbs)
9. Connect I/P harness to:
^ Blower motor connector.
^ Blower motor resistor connector.
^ HVAC module connector.
10. Install auxiliary duct assembly.
11. Install front rear duct by sliding forward on heater duct then down and rearward over rear duct.
12. Install control assembly housing/control assembly bracket assembly to floor and H-brace with attachment bolts.
Torque:
Control Assembly Bracket to Floor Bolts: 25 N.m (18 ft-lbs)
13. Install ignition lock cable to BTSI lever and control assembly housing.
14. Install transaxle shift cable to shift lever and control assembly housing.
15. Connect I/P wire harness connector to shifter assembly wire harness.
16. Attach I/P wire harness clips to control assembly bracket.
NOTE: Insulators are required between I/P retainer and cross car beam.
17. Insure that all I/P retainer to cross car beam interfaces have an insulator present, if not, install.
18. Install I/P retainer by aligning center 4-way locator (tapered boss) and outboard locators with corresponding holes/slots in cross car beam. Install fasteners and tighten from center.
Torque:
I/P Retainer to Cross Car Beam: 10 N.m (88 in-lbs)
19. Install right door sill plate trim.
20. Install DLC to retainer.
21. Install BCM to retainer.
22. Install I/P ground from H-brace (forward of BEC).
Torque:
I/P Ground to H-Brace: 10 N.m (88 in-lbs)
23. Install I/P BEC.
24. Install cluster connector to retainer.
25. Install intermediate ducts.
Torque:
Intermediate Duct Fasteners: 2.5 N.m (22 in-lbs)
26. Install right and left shifter closeout panels.
Torque:
Sifter Closeout Panel Screws: 2.5 N.m (22 in-lbs)
27. Install center shifter closeout panel.
28. Install passenger air bag.
Torque:
Air Bag Fasteners: 10 N.m (89 in-lbs)
29. Connect antenna, ground and I/P harness to radio.
30. Install radio.
Torque:
Radio Screws: 2.5 N.m (22 in-lbs)
31. Install cluster and cluster screws.
32. Install I/P top cover and fasteners.
Torque:
I/P Top Cover Fasteners: 2.5 N.m (22 in-lbs)
33. Install I/P top cover to cross car beam bolts.
Torque:
I/P Top Cover Bolts: 10 N.m (88 in-lbs)
34. Install TIP top cover attachment bolt covers by snapping into place.
35. Install A-pillar garnish moldings.
36. Install right deflector assembly to intermediate duct screw.
37. Snap cluster bezel into place and install screws.
Torque:
Cluster Bezel Screws: 2.5 N.m (22 in-lbs)
38. Install steering column shroud lower then upper.
39. Center temperature knob by aligning controller housing alignment tab with slot in gear/knob shaft.
40. Align temperature cable lug with detent spring point (this centers the door in the module).
41. Install temperature cable to HVAC control head by aligning retention tabs and temperature knob shaft and snapping into place.
42. Connect I/P harness to blower switch and HVAC controller.
43. Connect I/P harness to HVAC controller.
44. Connect I/P harness to:
^ Air bag telltale
^ Foglamp switch
^ Dimmer switch
^ Hazard switch
45. Install radio bezel by inserting upper front edge clips first, sliding bezel forward while holding down on front edge of bezel to engage upper retention clips then pressing forward at lower clip location engaging lower clips.
46. Install I/P front console storage compartment and screws.
Torque:
I/P Compartment Screws: 2.5 N.m (22 in-lbs)
47. Connect wire harness to window switches, mirror switch and cigar lighter.
48. Move shifter to neutral position.
49. Install front edge of horseshoe bezel first over shifter assembly making sure to engage alignment pins and front edge tabs with corresponding slots at bottom of radio bezel, clear wires and lower back edge snapping into place by pressing down.
50. Put shifter in Park position.
51. Connect I/P harness to doorjamb switch and install right end panel by inserting tabs at back panel with corresponding slots in I/P top cover and snapping into place by applying light force at clip locations.
52. Connect I/P harness to door jamb switch and install left end panel by inserting tabs at back of panel with corresponding slots in I/P top cover and snapping into place by applying light force at clip locations.
53. Install knee bolster by aligning retention clips with corresponding slots in retainer and snapping into place by applying light force at clip locations. Install screws.
Torque:
I/P Filler Panel Screws: 2.5 N.m (22 in-lbs)
54. Install heater hose to heater core inlet.
55. Position clamp at 9 o'clock.
56. Install heater hose to heater core outlet.
57. Position clamp at 9 o'clock position.
58. Insure mating surfaces are clean and free of debris, Using a new seal washer install liquid line thermal expansion valve (TXV).
Torque:
Seal Washer - Liquid Line-to-TXV: 16 N.m (12 ft-lbs)
59. Insure mating surfaces are clean and free of debris, using a new seal washer install suction hose to thermal expansion valve (TXV).
Torque:
Seal Washer - Suction Hose to TXV: 16 N.m (12 ft-lbs)
60. Install coolant.
61. Evacuate, add amount of oil measured during recovery (add evaporator amount if replaced), install refrigerant and check for leaks.