Tools Required

J 39400-A Halogen Leak Detector

1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Remove the bolt connecting evaporator lines to evaporator.
4. Remove the evaporator lines from the evaporator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Disconnect the heater hoses from the heater core. Refer to Heater Hoses Replacement .
7. Lower the vehicle.
8. Remove the evaporator case drain tube. Refer to Evaporator Tube Replacement .
9. Remove the inside and outside module attaching bolts and the accumulator mounting bracket bolt.
10. Remove the IP carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges and Console.
11. Remove the floor air outlet. Refer to Floor Air Outlet Replacement .
12. Disconnect the wiring harness from the HVAC module assembly.
13. Disconnect the electrical connections at the following locations:

•	The blower motor

•	The blower resistor




14. Remove the HVAC module assembly screw  (2) at the top of the module from the mounting bracket. (1).



15. Disconnect the gray source vacuum line  (1).

Important: DO NOT tilt HVAC module assembly or coolant may leak out.

16. Remove the module from the vehicle.

1. Install the HVAC module assembly in the vehicle.

Align the mounting bracket to the hole.




2. Connect the gray vacuum line (1).
3. Connect the electrical connections at the following locations:

•	The blower motor

•	The blower resistors

4. Connect the wiring harness to the HVAC module assembly.
5. Install the floor air outlet. Refer to Floor Air Outlet Replacement .
6. Install the IP carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges and Console.




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.

7. Install the upper module attaching bolts  (2).

Tighten
Tighten the bolts to 2 N·m (18 lb in).

8. Install the lower HVAC module assembly attaching bolts.

Tighten
Tighten the bolts to 2 N·m (18 lb in).

9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
10. Install the evaporator case drain tube. Refer to Evaporator Tube Replacement .
11. Connect the heater hoses to the heater core. Refer to Heater Hoses Replacement .
12. Lower the vehicle.
13. Connect the evaporator tube to the evaporator.

Tighten
Tighten the fittings to 24 N·m (18 lb ft).

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