Air Conditioning and Heater Module Assembly Removal and Installation

Air Conditioning and Heater Module Assembly Removal and Installation

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant from the A/C system.
2. Drain the cooling system.
3. Remove the left wiper arm linkage nuts.
Reposition the left wiper arm linkage for access.

Important: The defroster door must be closed to allow clearance during defroster duct removal.

4. Set the HVAC controls in the vent setting to close the defroster door.
5. Remove the blower motor.






6. Disconnect the electrical connector from the blower motor resistor.






7. Disconnect the electrical connector from the evaporator temperature sensor.
8. Disconnect all of the HVAC actuator electrical connectors.
9. Remove the IP carrier.






10. Remove the evaporator outlet tube nut.
11. Disconnect the evaporator outlet tube and evaporator inlet tube from the TXV.
12. Remove and discard the sealing washers.
13. Remove the heater inlet hose from the heater core.
14. Remove the heater outlet hose from the heater core.






15. Remove the HVAC module to dash panel sound barrier nuts.
16. Remove the HVAC module assembly from the cowl.

Installation Procedure

Important: Ensure proper alignment of the HVAC module assembly and HVAC module drain tube through the cowl.

1. Install the HVAC module assembly to the cowl.






2. Install the HVAC module assembly to dash panel sound barrier nuts.
Do not tighten the HVAC module assembly nuts at this time.
3. Install the heater outlet hose to the heater core.
4. Install the heater inlet hose to the heater core.
5. Install new sealing washers onto the evaporator inlet and outlet tubes.
6. Connect the evaporator inlet tube to the evaporator outlet tube.
7. Connect the evaporator inlet and outlet tubes to the TXV.






Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. Install the evaporator outlet tube nut at the TXV.

Tighten
Tighten the nut to 16 Nm (12 lb ft).

9. Install the IP carrier.
10. Connect all of the HVAC actuator electrical connectors.






11. Connect the electrical connector to the evaporator temperature sensor.






12. Connect the electrical connector to the blower motor resistor.
13. Install the blower motor.






14. Tighten the HVAC module assembly to dash panel sound barrier nuts.

Tighten
Tighten the nuts to 10 Nm (89 lb in).

15. Install the left wiper arm linkage.
16. Install the left wiper arm linkage nuts.

Tighten
Tighten the nuts to 5 Nm (44 lb in).

17. Fill the coolant system.
18. Evacuate and recharge the A/C system.
19. Leak test the fittings of the component using the J 39400-A.