Tools Required

J 39400-A Halogen Leak Detector

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the evaporator hose nut from the evaporator core.
5. Remove the evaporator hose from the evaporator core.
6. Remove and discard the sealing washers from the evaporator hose. Refer to Sealing Washer Replacement .
7. Remove the heater hoses from heater core. Refer to Heater Hoses Replacement .
8. Plug the heater core and the evaporator core openings to prevent leaking into the vehicle when removing the HVAC module.
9. Remove the I/P assembly. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages and Console.



10. Remove the evaporator drain.



11. Remove the defroster nozzle.



12. Remove the heater duct.



13. Remove the HVAC module nuts.
14. Remove the HVAC module from the vehicle.

1. Install the HVAC module to the vehicle.

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.

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




3. Install the heater duct.



4. Install the defroster nozzle.



5. Install the evaporator drain.
6. Install the I/P assembly. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages and Console.
7. Install the heater hoses to the heater core. Refer to Heater Hoses Replacement .
8. Install new sealing washers to the evaporator hose. Refer to Sealing Washer Replacement .
9. Install the evaporator hose to the evaporator core.
10. Install the evaporator hose nut to the evaporator core.

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

11. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
12. Leak test the fittings using the J 39400-A .
13. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.