HVAC Module Removal
REMOVAL1. Disable the Supplemental Inflatable Restraint (SIR) system.
2. Record pre-set radio stations.
3. Disconnect negative battery cable.
4. Recover refrigerant using an approved refrigerant recovery system.
5. Remove air cleaner housing cover and air induction hose at intake manifold.
6. Remove suction hose and liquid line from thermal expansion valve.
7. Remove thermal expansion valve from evaporator.
NOTICE: Place protective covers over A/C hoses, lines, TXV and HVAC module to prevent contamination of A/C system.
8. Remove coolant reservoir cap.
9. Drain cooling system.
10. Remove heater inlet hose from engine outlet and blow remainder of coolant out of heater core with an air hose in order to prevent coolant from spilling on vehicle interior when removing HVAC module
11. Install heater inlet hose on engine outlet and position clamp at 4 o'clock position as viewed from left side of vehicle.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
12. Raise vehicle.
13. Move clamps up heater core inlet and outlet hoses.
14. Remove hoses from heater core.
15. Lower vehicle.
16. Remove screws and carefully pull right and left end cap assemblies outward at clip locations.
17. Remove screws and remove arm rest, if equipped.
18. Lift parking brake lever.
19. Remove screw.
20. Remove parking brake cover by lifting straight off lever.
21. Move shifter to neutral. Remove ashtray from cup holder by lifting straight out.
22. Remove cup holder from console by pulling upwards starting at rear edge.
23. Remove ashtray bulb socket by lifting tab while sliding socket forward. Then pull socket straight out.
24. Remove wiring harness from cup holder.
25. Remove window/mirror switch, if equipped, by sliding switch forward then lifting at rear edge. Disconnect electrical connectors.
26. If vehicle does not have an arm rest, remove rear screw cover by lifting at cut out.
27. Remove rear console screws.
28. Remove left and right lower trim panel extensions by pulling outward at dual lock locations. Then rotate panels outward to disengage hinges from console.
29. Remove front console screws.
30. Move console rearward.
31. Disconnect cigarette lighter electrical connector.
32. Remove bulb socket from cigarette lighter by rotating clockwise and pulling straight out.
33. On automatic transmission equipped vehicles, tape shifter button in to clear shifter opening.
34. Lift console at rear. Slide console rearward and lift straight up to remove.
35. Depress center pins inward to release radio/HVAC controller cover push pin fasteners.
IMPORTANT: Do not push center pins through fasteners.
36. Remove fasteners and pull radio/HVAC controller cover rearward.
37. Disconnect traction control/fog lamp/rear defog electrical connector if equipped.
38. Remove radio screws.
39. Push spring clips in through D-holes on both sides of radio brace.
40. Pull radio out slightly to access rear of radio.
41. Disconnect electrical connector and antenna.
42. Remove radio.
43. Disconnect blower switch, A/C-Recirc and lighting electrical connectors.
44. Remove temperature and mode cables from HVAC control by squeezing lock tabs together while pulling cable housing straight up.
45. Remove cables from pins by pulling straight up. (Service cables shown in illustration.)
46. Remove screws and HVAC controller.
47. Remove closeout seal by releasing from tabs.
48. Remove screw and ground wire from H-bracket.
49. Remove wiring harness from H-bracket.
50. Remove screw and disconnect rear electrical connector from instrument panel junction block.
51. Remove instrument panel junction block screw.
52. Insert a small flat blade screwdriver from passenger side, to release lock tabs on instrument panel junction block and slide off of mounting pads.
53. Feed instrument panel junction block through H-bracket towards front of car.
54. Remove bolts from H-bracket.
55. Remove screws from data link connector (DLC) and steering column filler panel.
56. Remove hood release cable from lever by releasing cable housing, then rotating cable downward to cutout.
57. Remove steering column filler panel.
58. Disconnect ignition switch electrical connector at right steering column bolt.
59. Remove steering column bolts and lower column on front seat.
60. Remove fasteners and pull instrument cluster trim bezel rearward at clip locations.
61. Disconnect electrical connector from instrument panel dimmer switch.
62. Remove connector position assurance (CPA) devices and disconnect electrical connectors from instrument cluster by squeezing tabs on each side of connector.
63. Remove front and rear instrument cluster screws.
64. Remove instrument cluster.
65. Remove dimmer switch wiring harness from instrument panel reinforcement.
66. Feed connector through reinforcement towards front of car.
67. Remove passenger side air bag harness from cross car beam and energy absorber.
68. Remove glove box door stops by rotating 90 degrees and let door hang down.
69. Remove screws from glove box compartment and striker.
70. Remove glove box assembly by pulling rearward at clip locations.
71. Disconnect antenna cable at lower right side of instrument panel reinforcement.
IMPORTANT: Use illustration to determine fastener location and direction of removal.
NOTICE: Put instrument panel pad/reinforcement on a clean surface so that the surface does not become damaged.
72. Remove nut, screws and instrument panel pad/reinforcement assembly.
73. Remove I/P lower closeout panel by pulling out at the top edge, and then rotating the top downward.
74. For Sedans and Wagons, remove lower heater duct.
75. Lift rear floor heater duct off of mounting bolt and remove.
NOTICE: Be careful not to damage foam seal.
76. Remove screws and center air outlet duct.
Fig. 14 Windshield Defroster Nozzle Removal.:
77. Remove screws and unsnap windshield defroster nozzle from mode valve assembly.
78. Remove defroster nozzle by rotating front of nozzle up and away from windshield.
IMPORTANT: For SC1 and SC2 vehicles, leave defroster nozzle in place after disconnecting. Nozzle cannot be removed because of windshield rake angle.
79. Disconnect blower motor resistor connector.
80. Remove wire harness and hold down clips from HVAC module.
81. Disconnect blower motor and recirc motor electrical connectors.
82. Remove wiring harness and hold down clips from HVAC module.
83. Remove fuel vapor line and clip from HVAC module stud to gain access to nut.
84. Remove three screws and two nuts holding HVAC module to the cowl.
FASTENER LOCATIONS:
^ Bolt to the upper right side of TXV
^ Bolt below heater core outlet pipe.
^ Bolt just above HVAC module case drain.
^ Nut to the upper left of heater core inlet pipe (below TXV).
^ Nut on left side of cowl.
IMPORTANT: Lower fasteners may be easier to access by raising vehicle.
85. Remove HVAC module from vehicle.