Tools Required

1. Disable the SIR system. Refer to Enabling the SIR System in SIR.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Remove the cruise control and the bracket. Position the components out of the way.



4. Disconnect the A/C lines from the evaporator.



5. Remove the heater hoses from the heater core. Pinch off the hoses in order to prevent leaking.



6. Remove the condensate drain tube.
7. Remove the instrument panel assembly. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges and Console.



8. Remove the defroster duct (3).



9. Remove the auxiliary floor duct connector.
10. Remove the left side window defroster ducts (1).



11. Remove the right side window defroster ducts (1).
12. Remove the passenger air bag.
13. Remove the powertrain control module (PCM) and the bracket. Refer to Powertrain Control Module Replacement/Programming in Engine Controls-3.8L or Powertrain Control Module Replacement/Programming in Engine Controls-4.0L, 4.6L.
14. Remove the right center instrument panel (IP) mounting bracket.
15. Disconnect the electrical connectors from the module.



16. Remove the heating, ventilation, and air conditioning (HVAC) module nuts (1).
17. Remove the HVAC module (2).

Tools Required

J 39400 Electronic Halogen Leak Detector

1. Install the heating, ventilation, and air conditioning (HVAC) module assembly (2).

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.

2. Install the HVAC module nuts (1) to the dash.

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

3. Connect the electrical connectors to the module.
4. Install the right center instrument panel (IP) mounting bracket.
5. Install the powertrain control module (PCM) and the bracket. Refer to Powertrain Control Module Replacement/Programming in Engine Controls-3.8L or Powertrain Control Module Replacement/Programming in Engine Controls-4.0L, 4.6L.
6. Install the passenger air bag.



7. Install the left side window ducts (1).

Tighten
Tighten the fasteners to 2.5 N·m (23 lb in).




8. Install the right side window ducts (1).

Tighten
Tighten the fasteners to 2.5 N·m (23 lb in).

9. Install the auxiliary duct connector.



10. Install the defroster duct (3) and the fasteners (1,2).

Tighten
Tighten the screws to 2.5 N·m (23 lb in).

Tighten
Tighten the nuts to 9 N·m (65 lb in).

11. Install the IP assembly. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges and Console.
12. Install the cruise control and the bracket assembly.



13. Install the condensate drain tube.



14. Install the heater hoses to the heater core.



15. Install the A/C lines to the evaporator.

Tighten
Tighten the nuts to 24 N·m (18 lb ft).

16. Enable the supplemental inflatable restraint (SIR) system. Refer to Enabling the SIR System in SIR.
17. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
18. Using the J 39400 , leak test the A/C system. Refer to Leak Testing .