Tools Required

J 39400-A Electronic Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L or Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the cross vehicle beam. Refer to Instrument Panel Tie Bar Replacement in Instrument Panel, Gauges and Console.
5. Disconnect the A/C lines at the evaporator block fitting. Refer to Accumulator Tube Replacement .
6. Disconnect the heater hoses at the heater core. Refer to Heater Hoses Replacement .
7. Disconnect the vacuum hoses.
8. Disconnect the electrical connectors.




Important: Position the heater core outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly.

9. Remove the heater core outlet cover screws.
10. Remove the heater core outlet cover.



11. Remove the evaporator drain elbow.



12. Remove the HVAC control module to dash nuts.
13. Remove the HVAC control module.



14. Remove all of the outer HVAC control module seals (1, 2, 3).

1. Install new outer HVAC control module seals (1, 2, 3).
2. Install the HVAC control 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.

3. Install the HVAC control module to dash nuts.

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




4. Install the evaporator drain elbow.
5. Connect the electrical connectors.
6. Connect the vacuum hoses.



7. Install the heater core outlet cover.
8. Install the heater core outlet cover screws.

Tighten
Tighten the heater core outlet cover screws to 1.5 N·m (13 lb in).

9. Install the cross vehicle beam. Refer to Instrument Panel Tie Bar Replacement in Instrument Panel, Gauges and Console.
10. Connect the heater hoses at the heater core. Refer to Heater Hoses Replacement .
11. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
12. Install the A/C lines at the evaporator block fitting. Refer to Accumulator Tube Replacement .
13. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L or Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
14. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
15. Leak test the fittings of the component using J 39400-A .