Housing Assembly HVAC: Service and Repair

HVAC MODULE ASSEMBLY REPLACEMENT

TOOLS REQUIRED
- J 39400-A Halogen Leak Detector
- J 38185 Hose Clamp Pliers

REMOVAL PROCEDURE
1. Recover the refrigerant.




2. Remove the evaporator hose nut.
3. Disconnect the evaporator hose connection from the evaporator.
4. Using the J 38185 reposition the hose clamps.




5. Remove the heater hoses (1, 2) from the heater core.
6. Plug the heater core and evaporator openings to prevent leaking into the vehicle when removing module assembly.
7. Pinch off the hoses in order to prevent leaking.
8. Remove the IP assembly.
9. Remove the lower IP support bracket.




10. Remove the defroster duct retaining screws (1,2) and nut (3).
11. Remove the defroster duct.
12. Remove the air distributor duct screws and duct.




13. Disconnect the blower control module (1) connection.
14. Disconnect the I/P to HVAC module (2) connection.




15. Remove the HVAC module retaining nuts (1-5).
16. Remove the HVAC module.

INSTALLATION PROCEDURE




1. Install the HVAC module.
2. Install the HVAC module nuts to the cowl (1-5).

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten
Tighten the nuts to 9 N.m (80 lb in).




3. Connect the blower control module (1) connection.
4. Connect the I/P to HVAC module connector (2).




5. Install the defroster duct and the module mounting screws (1, 2).

Tighten
Tighten the screws to 1.4 N.m (12 lb in).

6. Install the defroster duct mounting nut (3) to the front of dash.

Tighten
Tighten the nut to 9 N.m (80 lb in).

7. Install the air distributor duct and screws.

Tighten
Tighten the screws to 1.4 N.m (12 lb in).

8. Install the lower IP support bracket.
9. Install the IP assembly.




10. Install the heater hoses (1, 2) to the heater core.
11. Using the J 38185 Reposition the hose clamps into their original position.




12. Connect the evaporator hose connection to the evaporator.
13. Install the evaporator hose nut.

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

14. Recharge the A/C system.
15. Leak test the fittings of the component using the J 39400-A.
16. Refill the engine coolant.