Housing Assembly HVAC: Service and Repair

HVAC Module Assembly Replacement


REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable.
2. Remove the instrument panel assembly.
3. Remove the instrument panel reinforcement.
4. Disconnect the blower motor electrical connector.
5. Disconnect the blower motor resistor electrical connector (4).
6. Disconnect the A/C compressor control module electrical connector (1).




7. Drain the engine cooling system. Refer to Draining and Filling Cooling System.
8. Remove the heater hoses (1,2) at the heater core.




9. Discharge and recover the Refrigerant. Refer to Refrigerant Recovery and Recharging.
10. Remove the cruise control servo (if equipped).

IMPORTANT: Cap the open fittings to prevent dirt and moisture from entering the refrigeration system.

11. Remove the evaporator inlet (2) and outlet (1) tubes from the evaporator.




12. Separate the rear heater ducts (1) from the HVAC module assembly.
13. Remove the six nuts.
14. Pull the HVAC module assembly forward and remove from the vehicle.

INSTALLATION PROCEDURE




1. Install the HVAC module assembly to the vehicle.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the six nuts.

Tighten
Tighten the nuts to 10 N.m (89 lb in).

3. Connect the rear heater ducts (1) to the HVAC module assembly.




4. Install new O-ring lubricated with 525 Viscosity mineral oil.
5. Install the evaporator inlet (2) and outlet (1) tubes to the evaporator.

Tighten
Tighten the inlet tube (2) to 25 N.m (19 lb ft).

Tighten
Tighten the outlet hose (1) to 38 N.m (28 lb ft).




6. Connect the A/C compressor control module electrical connector (1).
7. Connect the blower motor resistor electrical connector (4).
8. Connect the blower motor electrical connector.




9. Install the instrument panel reinforcement.
10. Install the instrument panel assembly.
11. Install the heater hoses (1,2) to the heater core.
12. Fill the cooling system. Refer to Draining and Filling Cooling System.
13. Evacuate and Recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
14. Install the cruise control servo (if removed).
15. Connect the negative battery cable.

Tighten
Tighten the negative battery cable to 15 N.m (11 lb ft).

16. Operate the A/C system and test for refrigerant leaks. Refer to Leak Testing.