Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.



3. 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.




4. Remove the evaporator tube extension block fitting bolt.
5. Remove the IP carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges and Console.



6. Remove the IP support bracket bolt from the IP.
7. Remove the IP support bracket.



8. Disconnect the vacuum line connection at the cowl.



9. Disconnect the vacuum actuator electrical connectors.
10. Disconnect the vacuum lines from the vacuum actuators.



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



13. Remove the heater core pipe retaining bracket screw.
14. Remove the heater core pipes.



15. Remove the HVAC module to cowl screws.



16. Remove the HVAC module to IP support nut.



17. Remove the LH/RH rear supply duct screws from the module.
18. Remove the ducts from the HVAC module.
19. Reposition the wiring harness to allow the removal of the module.



20. Remove the HVAC module.

1. Install the HVAC module.
2. Position the wiring harness to facilitate the module.



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




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.

5. Install the HVAC module to IP support nut.

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




6. Install the HVAC module to cowl screws.

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




7. Install the heater core inlet and outlet pipes:

•	Use new O-rings.

•	Lightly lubricate the O-rings with coolant.

8. Install the heater core pipe retaining bracket screw.

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




9. Install the heater core pipe bracket.
10. Install the heater core pipe bracket screw.

Tighten
Tighten the screw to 1.6 N·m (14 lb in).




11. Install the IP support bracket.
12. Install the IP support bracket bolts.

Tighten
Tighten the bolts to 22 N·m (16 lb ft).

13. Connect the vacuum actuator electrical connectors.
14. Connect the vacuum lines to the vacuum actuators.



15. Connect the vacuum line connection at the cowl.
16. Install the IP carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages and Console.



17. Install the evaporator tube extension block fitting bolt.

Tighten
Tighten the bolt to 20 N·m (15 lb ft).




18. 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.

19. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
20. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
21. Leak test the fittings of the component using J 39400-A .