HVAC Module Assembly Replacement - Auxiliary

HVAC MODULE REPLACEMENT - AUXILIARY

TOOLS REQUIRED
J 39400-A Halogen Leak Detector

REMOVAL PROCEDURE
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the left rear quarter trim panel.
3. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Raise and support the vehicle. Refer to Vehicle Lifting.
5. Remove the level ride air compressor.




6. Remove the auxiliary A/C line block fitting bolt.
7. Disconnect the A/C line block fitting.
8. Remove and discard the sealing washers.
9. Cap or tape the A/C lines.

IMPORTANT: Cap or tape the open A/C refrigerant lines immediately to prevent system contamination.




10. Disconnect the auxiliary heater hoses from the heater core pipes.
11. Lower the vehicle.




12. Remove the air distribution duct mounting bolts.
13. Remove the air distribution duct mounting retainer.
14. Disconnect the air distribution duct from the HVAC module.
15. Disconnect the auxiliary blower motor electrical connector.
16. Disconnect the auxiliary blower motor resistor electrical connector.
17. Disconnect the auxiliary temperature actuator electrical connector.




18. Remove the HVAC module assembly mounting bolts and nut.
19. Disconnect the left PSD module from the mounting bracket and reposition aside.
20. Remove the HVAC module assembly from the vehicle.
21. Remove and discard the HVAC module assembly to body seals.

INSTALLATION PROCEDURE
1. Install new HVAC module assembly to body seals.




2. Install the HVAC module assembly to the vehicle.
3. Install the HVAC module assembly mounting bolts and the nut.

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

NOTE: Refer to Fastener Notice in Service Precautions.

4. Connect the left PSD module to the mounting bracket.




5. Connect the auxiliary temperature actuator electrical connector.
6. Connect the electrical connector to the auxiliary blower motor resistor.
7. Connect the auxiliary blower motor electrical connector.
8. Connect the auxiliary air distribution duct to the HVAC module assembly.
9. Install the auxiliary air distribution duct mounting bolts.

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

10. Install the air distribution duct mounting retainer.
11. Raise and support the vehicle. Refer to Vehicle Lifting.




12. Connect the auxiliary heater hoses to the heater core pipes.
13. Remove the cap or tape from the A/C lines.
14. Install the new sealing washers onto the A/C line.




15. Install the auxiliary A/C line block fitting bolt.

Tighten the bolt to 20 N.m (15 lb ft).

16. Install the level ride air compressor.
17. Lower the vehicle.
18. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
19. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
20. Leak test the fittings of the component using J 39400-A.
21. Install the left rear quarter trim panel.