Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the instrument panel pad. Refer to Instrument Panel Upper Trim Pad Replacement in Instrument Panel, Gages, and Console.
5. Remove the inflatable instrument panel restraint module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
6. Remove the right side HVAC duct from the HVAC unit.
7. Remove the lower radio bracket. Refer to Radio Housing Bracket Replacement in Entertainment.
8. Remove the instrument panel right end bracket. Refer to Instrument Panel End Bracket Replacement - Right Side in Instrument Panel, Gages, and Console.
9. Remove the instrument panel center support bracket. Refer to Instrument Panel Center Support Bracket Replacement in Instrument Panel, Gages, and Console.
10. Remove the radio antenna lead from the three retaining clips on the HVAC unit.
11. Mark and remove the heater hoses from the heater core pipes.
12. Disconnect the water valve vacuum hose.
13. Disconnect the vacuum supply hose from the check valve.
14. Remove the Thermal Expansion Valve (TXV). Refer to Thermal Expansion Valve Replacement .
15. Remove the fuel line retaining bracket and nut from the HVAC mounting stud.
16. Remove the HVAC unit mounting stud and screws.
17. Remove the HVAC unit from the vehicle.

1. Install the HVAC module assembly to the vehicle.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the screws from inside the vehicle which secure the HVAC module assembly to the dash.

Tighten
Tighten the nuts to 6 N·m (53 lb in).

3. Install the screws from inside the engine compartment which secure the HVAC module assembly to the dash.

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

4. Install the fuel line retaining bracket and nut to the HVAC mounting stud.

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

5. Install the Thermal Expansion Valve (TXV). Refer to Thermal Expansion Valve Replacement .
6. Connect the vacuum supply hose to the check valve.
7. Connect the water valve vacuum hose.
8. Install the heater hoses to the heater core pipes.
9. Install the radio antenna lead to the three retaining clips on the HVAC unit.
10. Install the instrument panel center support bracket. Refer to Instrument Panel Center Support Bracket Replacement in Instrument Panel, Gages, and Console.
11. Install the instrument panel right end bracket. Refer to Instrument Panel End Bracket Replacement - Right Side in Instrument Panel, Gages, and Console.
12. Install the lower radio bracket. Refer to Radio Housing Bracket Replacement in Entertainment.
13. Install the right side HVAC duct to the HVAC unit.
14. Install the inflatable instrument panel restraint module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
15. Install the instrument panel pad. Refer to Instrument Panel Upper Trim Pad Replacement in Instrument Panel, Gages, and Console.
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
17. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
18. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
19. Leak test the fittings of the component using J 39400-A .