Housing Assembly HVAC: Service and Repair

HVAC MODULE ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE




1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Disconnect the battery negative cable.
3. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the heater hose quick connects from the heater core pipes:
^ Raise the air inlet screen on the passenger side and open the access door near the pollen filter.
^ Squeeze the tabs on the locking collar and pull back on the sleeve to unlock.
^ Carefully pull back the tabs to remove the disconnects.
^ Discard the green assembly markers (1) if attached.




5. Remove the evaporator line extension bolt from the cowl.
6. Remove the steering column.
7. Remove the I/P carrier.




8. Remove the vacuum line connection at the cowl.




9. Disconnect the electrically operated actuator connectors.




10. Remove the heater core pipe bracket screw.
11. Remove the heater core pipe bracket.




12. Remove the heater core inlet and outlet pipe retaining bracket screw.
13. Remove the heater core inlet and outlet pipes.




14. Remove the I/P support brace bolt from the I/P.
15. Remove the I/P support brace bolt from the transmission well.
16. Remove the I/P support brace.
17. Remove the following components from the vacuum actuators:
^ The vacuum hoses
^ The electrical connections




18. Remove the two air distribution module engine compartment screws.




19. Remove the module interior nut.




20. Remove the LH/RH floor rear supply duct screws from the module.
21. Remove the ducts from the module.
22. Reposition the wiring harness to allow the removal of the module.




23. Remove the module:
^ Carefully lift the upper vents from under the rubber seal.
^ Angle the module outward to remove.

INSTALLATION PROCEDURE




1. Install the air distribution module.
2. Position the wiring harness to facilitate the I/P carrier installation.




3. Install the RH/LH floor rear supply ducts.
4. Install the duct screws until fully seated and not stripped.

NOTE: Refer to Fastener Notice in Service Precautions.




5. Install the module interior nut.

Tighten
Tighten the module interior nut to 4 N.m (35 lb in).




6. Install the module engine compartment screws.

Tighten
Tighten the screws to 4 N.m (35 lb in).

7. Install the following vacuum actuator components:
^ The electrical connections
^ The hoses




8. Position the I/P support brace at the I/P and at the transmission well.
9. Install the I/P support brace bolts at the I/P and at the transmission well.

Tighten
Tighten the I/P support brace bolts to 22 N.m (16 lb ft).




10. Install the heater core inlet and outlet pipes:
^ Use new O-rings.
^ Lightly lubricate the O-rings with coolant.
11. Install the heater core inlet and outlet pipe retaining bracket screw.

Tighten
Tighten the retaining bracket screw to 5 N.m (44 lb in).




12. Install the heater core pipe bracket.
13. Install the heater core pipe bracket screw until fully seated and not stripped.
14. Connect the electrically operated actuator connectors.




15. Connect the vacuum line connection at the cowl.
16. Install the I/P carrier.
17. Install the steering column.




18. Install the evaporator line extension bolt to the cowl.

Tighten
Tighten the evaporator line extension bolt to 20 N.m (15 lb ft).




19. Install the heater hose quick connects to the heater core pipe connections:
^ Discard green assembly marker (1) if not attached to the quick connect.
^ Inspect that the quick connects are fully seated.
^ Squeeze the locking tabs (2) and push the retaining sleeve (3) into the locked position.
^ Close the access door near the pollen filter and lower the air inlet screen on the passenger side.
20. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
21. Connect the battery negative cable.
22. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
23. Leak test the fitting(s) of the repaired or reinstalled component using J 39400-A.