Heating, Ventilation, and Air Conditioning

Air Conditioning (A/C) Evaporator and Blower Module Assembly Replacement

Removal Procedure

Tools Required

J 39400-A Halogen Leak Detector

1. Remove the HVAC module from the vehicle.




2. Remove the fasteners from the heater core cover and remove the cover.




3. Remove the heater core.




4. Remove the lower HVAC case screws.




5. Unsnap and open the passenger compartment filter door.
6. Remove the lower HVAC case.




7. Remove the evaporator core.

Installation Procedure




1. Install the evaporator core into the HVAC module assembly.






Important: Verify that the orifice plate is correctly positioned in the HVAC module. Verify that the lower HVAC case is properly positioned and is fully seated on the HVAC module before installing the screws. Install all of the lower HVAC case screws.

2. Install the lower HVAC case.






Notice: Refer to Fastener Notice.

3. Install the lower HVAC case screws.

Tighten the screws to 1.8 N.m (15 lb in).

4. Close and secure the passenger compartment filter door.




5. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
6. Install the heater core into the HVAC module.






Important: Verify that the heater core cover is properly positioned and is fully seated on the HVAC module before installing the screws. Install all of the heater core cover screws.

7. Install the heater core cover and the screws.

Tighten the screws to 1.8 N.m (15 lb in).




8. Replace the drain tube seal.




9. Replace the front of dash seal.
10. Inspect and replace the following HVAC module seals if damaged:

* The defrost duct seal
* The HVAC module to cross car duct seal
* The center air outlet duct seal
* The center floor air outlet duct seal
* The air inlet seal

11. Install the HVAC module in the vehicle.
12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
13. Leak test the fittings using J 39400-A.
14. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ) Static Fill) Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5) Static Fill) Draining and Filling Cooling System (GE 47716 Fill).