Tools Required

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. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
5. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
6. Remove the instrument panel (I/P) trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gages, and Console.
7. Remove the bolt from the accessory wiring junction block.
8. Disengage the junction block tabs from the passenger knee bolster. Remove the junction block from the knee bolster.
9. Remove the brake pedal nut and bolt.
10. Remove the brake pedal brace bolts from the I/P carrier cross car beam.
11. Lower the body control module (BCM) away from the I/P carrier.
12. Disconnect any ground wires, as necessary.
13. Reposition the I/P wiring harness out of the way.



14. Remove the bracket bolt from the HVAC module assembly right support (2).
15. Remove the bracket bolts from the HVAC module assembly lower support (1).



16. Remove the bracket bolts from the HVAC module assembly upper support.
17. Remove the right and the left I/P carrier bolts.
18. Remove the I/P carrier.



19. Remove the nut that secures the evaporator tube to the TXV.
20. Disconnect the evaporator tube from the TXV.
21. Remove the seal washers and discard.



22. Use J 38185 in order to position aside the inlet heater hose clamp at the heater core.
23. Use J 38185 in order to position aside the outlet heater hose clamp at the heater core.
24. Disconnect the inlet heater hose from the heater core.
25. Disconnect the outlet heater hose from the heater core.
26. Disconnect the electrical connectors from the HVAC module assembly.



27. Remove the evaporator drain elbow.



28. Remove the nuts which secure the HVAC module assembly to the dash.
29. Remove the HVAC module assembly.



30. Remove all of the seals (1, 2, 3) from the outer HVAC module assembly.

1. Install new seals (1, 2, 3) to the outer HVAC module assembly.
2. Install the HVAC module assembly to the vehicle.

Notice: Refer to Fastener Notice in the Preface section.




3. Install the nuts which secure the HVAC module assembly to the dash.

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




4. Install the evaporator drain elbow.
5. Connect the electrical connectors to the HVAC module assembly.
6. Install the I/P carrier to the vehicle. Align the I/P carrier to the HVAC module assembly and the hinge pillars.
7. Install the bolts to the right and the left I/P carrier.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




8. Install the bolts to the HVAC module assembly upper support bracket.

Tighten
Tighten the bolts to 4 N·m (36 lb in).




9. Install the bolts to the HVAC module assembly lower support bracket (1).

Tighten
Tighten the bolts to 4 N·m (36 lb in).

10. Install the bolt to the HVAC module assembly right support bracket (2).

Tighten
Tighten the bolt to 4 N·m (36 lb in).

11. Position the I/P wiring harness to the original position.
12. Connect any disconnected ground wires.
13. Install the BCM.
14. Install the brake pedal brace bolts to the I/P carrier.
15. Position the brake pedal to the brake pedal brace.
16. Install the brake pedal bolt and nut. Refer to Brake Pedal Assembly Replacement In Hydraulic Brakes.
17. Seat the bottom junction block tabs and snap the top of the junction block to the passenger knee bolster.
18. Install the junction block bolt.

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

19. Install the I/P trim pad. Refer to Instrument Panel Trim Pad Replacement .



20. Connect the inlet heater hose to the heater core.
21. Connect the outlet heater hose to the heater core.
22. Use J 38185 in order to reposition the inlet heater hose clamp to the heater core.
23. Use J 38185 in order to reposition the outlet heater hose clamp to the heater core.
24. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
25. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
26. Install new sealing washers on the evaporator tube. Refer to Sealing Washer Replacement .



27. Connect the evaporator tube to the TXV.
28. Install the evaporator tube to the TXV block fitting nut.

Tighten
Tighten the nut to 17 N·m (13 lb ft).

29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
30. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
31. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
32. Leak test the fittings of the component using J 39400-A .