Housing Assembly HVAC: Service and Repair

HVAC MODULE ASSEMBLY REPLACEMENT

^ J 43600 ACR 2000 Air conditioning Service Center
^ J 38185 Hose Clamp Plier
^ J 39400-A Halogen Leak Detector

REMOVAL PROCEDURE




1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Drain the coolant. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the evaporator hose nut.
4. Disconnect the evaporator hose connection at the evaporator.




5. Remove the heater hoses from the heater core using the J 38185.
6. Plug the heater core and evaporator openings to prevent leaking into the vehicle when removing module assembly.




7. Remove the IP assembly. Refer to IP Carrier Replacement in Instrument Panel, Gauges and Warning Indicators.
8. Remove the defroster duct retaining screws (1,2).
9. Remove the defroster duct nut (3).
10. Remove the defroster duct.
11. Remove the air distributor duct screws.
12. Remove the air distributor 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.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the HVAC module nuts to the dash (1-5). Refer to the illustration for the HVAC module fastener torque sequence.

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




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




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

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

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

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

8. Install the air distributor duct.
9. Install the air distributor duct screws.

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

10. Install the IP assembly. Refer to IP Carrier Replacement in Instrument Panel, Gauges and Warning Indicators.




11. Install the heater hoses to the heater core using the J 38185.

IMPORTANT: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.

Flat washer type seals do not require lubrication.




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. Refer to Refrigerant Recovery and Recharging.
15. Leak test the component using the J 39400-A.
16. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.