HVAC Module Assembly Replacement LHD Bench Overhaul

1. Remove the HVAC module.
2. Remove and discard the cowl panel seals.



3. Remove the mode valve assembly screws and clips.
4. Lift the mode valve assembly straight up to remove from HVAC module.



5. Remove the upper air inlet case screws and spring clips.
6. Lift the upper air inlet case assembly straight up to remove from lower case assembly.



7. Remove the evaporator pipe clamp and screw.
8. Lift the evaporator straight up to remove from lower case assembly.

1. Assemble the water filter, retainers, evaporator seal and spacer pad to the new evaporator. Add 67 ml (2.25 oz) of PAG refrigerant oil and replace evaporator pipe cover.

Evaporator part will come with filter and pad already installed. 67 ml (2.25 oz) of oil will still have to be added to the evaporator.

2. Lower the evaporator into the lower case assembly.
3. Install the evaporator pipe clamp and the screw.

Important: Make sure the evaporator pipes are wrapped with mastic on part being installed.




4. Place the upper air inlet case on the lower case assembly.

Notice: Make sure all tongue and groove parts fit properly before tightening screws to avoid case damage.

5. Install the upper air inlet case screws and spring clips.




Notice: Make sure all tongue and groove parts fit properly before tightening screws to avoid case damage.

6. Install the mode valve and screws.

HVAC Module Assembly Replacement LHD

1. Disable the SIR system. (Refer to "Disabling the SIR System" in this service manual.)
2. Record the pre-set radio stations.
3. Disconnect the negative battery cable.
4. Recover the refrigerant using an approved refrigerant recovery system.
5. Remove the air cleaner housing cover and air induction hose at the intake manifold.



6. Remove the suction hose and liquid line from the thermal expansion valve.



7. Remove the thermal expansion valve from the evaporator.

Notice: Place protective covers over A/C hoses, lines, TXV, and HVAC module to prevent contamination of A/C system.

8. Remove the coolant reservoir cap
9. Drain the cooling system.
10. Remove the heater inlet hose from the engine outlet and blow remainder the coolant out of the heater core with an air hose in order to prevent coolant from spilling on the vehicle interior when removing HVAC module.
11. Install the heater inlet hose on the engine outlet and position clamp at 4 o'clock position as viewed from the left side of the vehicle.




Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

12. Raise the vehicle.
13. Move the clamps up the heater core inlet and outlet hoses.



14. Remove the hoses from the heater core
15. Lower the vehicle.



16. Remove the screws and carefully pull right and left end cap assemblies outward at clip locations.



17. Remove the screws and remove the arm rest, if equipped.



18. Lift the parking brake lever.
19. Remove the screw.
20. Remove the parking brake cover by lifting straight off lever.



21. Move the shifter to neutral. Remove the ashtray from the cup holder by lifting straight out.
22. Remove the cup holder from the console by pulling upwards starting at the rear edge.



23. Remove the ashtray bulb socket by lifting tab while sliding socket forward. Then pull socket straight out.
24. Remove the wiring harness from the cup holder.



25. Remove the window/mirror switch, if equipped, by sliding switch forward then lifting at the rear edge. Disconnect the electrical connectors.



26. If the vehicle does not have an arm rest, remove the rear screw cover by lifting at cut out.
27. Remove the rear console screws.



28. Remove left and right lower trim panel extensions by pulling outward at dual lock locations. Then rotate the panels outward to disengage hinges from console.



29. Remove the front console screws.
30. Move console rearward.
31. Disconnect the cigarette lighter electrical connector.
32. Remove the bulb socket from cigarette lighter by rotating clockwise and pulling straight out.



33. On automatic transmission equipped vehicles, tape the shifter button in to clear shifter opening.
34. Lift the console at rear. Slide the console rearward and lift straight up to remove.



35. Depress the center pins inward to release radio/HVAC controller cover push pins fasteners.

Important: Do not push the center pins through fasteners.

36. Remove the fasteners and pull radio/HVAC controller cover rearward.
37. Disconnect traction control/fog lamp/rear defog electrical connector if equipped.



38. Remove the radio screws.
39. Push the spring clips in through D-holes on both sides of radio brace.
40. Pull the radio out slightly to access the rear of the radio.



41. Disconnect the electrical connector and antenna.
42. Remove the radio.



43. Disconnect blower switch, A/C-Recirc and lighting electrical connectors.



44. Remove the temperature and mode cables from HVAC control by squeezing lock tabs together while pulling cable housing straight up.
45. Remove the cables from pins by pulling straight up. (Service cables shown in illustration.



46. Remove the screws and HVAC controller.



47. Remove the closeout seal by releasing from tabs.



48. Remove the screw and ground wire from H-bracket.
49. Remove the wiring harness from H-bracket.



50. Remove the screw and disconnect the rear electrical connector from the instrument panel block screw.



51. Remove the instrument panel junction block screw.
52. Insert a small flat blade screwdriver from passenger side, to release lock tabs on the instrument panel junction block and slide off of mounting pads.
53. Feed the instrument panel junction block through H-brackets towards the front of the car.



54. Remove the bolts from H-Bracket.



55. Remove the screws from the data link connector(DLC) and steering column filer panel.



56. Remove the hood release cable from the lever by releasing the cable housing, then rotating the cable downward to cutout.
57. Remove the steering column filler panel.



58. Disconnect the ignition switch electrical connector at the right steering column bolt.
59. Remove the steering column bolts and the lower column on the front seat.



60. Remove the fasteners and pull the instrument cluster trim bezel rearward at clip locations.
61. Disconnect the electrical connector from the instrument panel dimmer switch.



62. Remove the connector position assurance (CPA) devices and disconnect the electrical connectors from the instrument cluster by squeezing the tabs on each side of connector.



63. Remove the front and rear instrument cluster screws.
64. Remove the instrument cluster.



65. Remove the dimmer switch wiring harness from the instrument panel reinforcement.
66. Remove the passenger side air bag harness from cross car beam and energy absorber.



67. Remove the passenger side air bag harness from the cross car beam and energy absorber.



68. Remove the glove box door stops by rotating 90 degrees and let door hang down.
69. Remove the screws from the glove box and compartment and striker.
70. Remove the glove box assembly by pulling rearward at the clip locations.



71. Disconnect the antenna cable at the lower right side of the instrument panel reinforcement.



72. Use the illustration to determine fastener location and direction of removal.



73. Remove the nut, screws and instrument panel pad/reinforcement assembly.



74. Remove the I/P lower closeout panel by pulling out at the top edge, and then rotating the top downward.



75. For Sedans and Wagons, remove the lower heater duct. (Refer to Heater Core Removal" in this service manual.)
76. Lift rear floor heater duct off of the mounting bolt and remove.

Notice: Be careful not to damage foam seal.




77. Remove the screws and center air outlet duct.



78. Remove the screws and unsnap windshield defroster nozzle from the mode valve assembly




Important: For SC1 and SC2 vehicles, leave the defroster nozzle in place after disconnecting. Nozzle cannot be removed because of windshield rake angle.

79. Remove the defroster nozzle by rotating front of nozzle up and away from the windshield.



80. Disconnect the blower motor resistor connector.
81. Remove the wire harness and hold down clips from the HVAC module.



82. Disconnect the blower motor and recirc motor electrical connectors.



83. Remove the wiring harness and hold down the clips from the HVAC module.



84. Remove the fuel vapor line and clip from the HVAC module stud to gain access to the nut.
85. Remove the three screws and two nuts holding the HVAC module to the cowl.

Fastener Locations:





•	Bolt to the upper right side of TXV.

•	Bolt below to the heater core outlet pipe.

•	Bolt just above the HVAC module case drain.

•	Nut to the upper left of heater core inlet pipe (below TXV).

•	Nut on the left side of the cowl

Important: Lower the fasteners may be easier to access by raising vehicle.




86. Remove the HVAC module from the vehicle.

1. Install the new cowl panel seals on the heater core pipes, case drain, and evaporator block.



2. Install the HVAC module through the cowl. Install the screws and nuts.

Tighten
Tighten to 5 N·m (44 lbs in)

3. Install the fuel vapor line and clip to stud below TXV.



4. Connect the blower motor and recirc motor electrical connectors.
5. Install the wire harness hold down clips on HVAC module.



6. Connect the blower motor resistor electrical connector.
7. Install the wire harness hold down clips on the HVAC module.



8. Rotate the windshield defroster nozzle onto mode valve assembly and install screws. Make sure the duct is snapped on both sides of HVAC module.

Tighten
Tighten to 2.2 N·m (20 lbs in)




9. Install the center air outlet duct and screws.

Tighten
Tighten to 10 N·m (89 lbs in).

Important: Make sure that the plastic right mounting tab is between knee beam and mounting bracket.




10. For SL and SW only, install the rear floor heater duct and place on mounting stud.

Notice: Be careful not to damage foam seal.

11. Install the lower heater duct.



12. Install the instrument panel pad/reinforcement assembly.

Important: Make sure wiring harnesses and instrument panel junction block are in position.

13. Install and tighten the nut and bolts.

Tighten
Tighten to 10 N·m(89 lbs in).




14. Connect the antenna cable at lower right side of the instrument panel reinforcement.



15. Install the glove box and snap in at the clip locations.
16. Install and tighten the screws.

Tighten
Tighten to 2.2 N·m (20 lb in).

17. Install the glove box door stops.
18. Adjust the striker as necessary.



19. Install the passenger side air bag harness to energy absorber and cross-car beam



20. Install the dimmer switch wiring harness to instrument panel reinforcement.



21. Install the instument cluster.
22. Install and tighten the screws.

Tighten
Tighten to 3 N·m (26 lbs in).




23. Connect the electrical connectors to the instrument cluster.
24. Install the CPA.



25. Connect the electrical connector to the dimmer switch.
26. Install the instrument cluster trim bezel. Push in at the clip locations.
27. Install the push pin fasteners.



28. Raise the steering column into position.
29. Install and tighten the bolts.

Tighten
Tighten the 35 N·m (26 lbs ft).

30. Connect the ignition switch electrical connector at the right steering column bolt.



31. Route the hood release cable through I/P and then install release cable to lever.



32. Install the steering column filler panel and DLC.
33. Install and tighten the screws.

Tighten
Tighten to 2.2 N·m (20 lbs in).




34. Install and tighten bolts into H-bracket.

Tighten
Tighten bolts to 25 N·m (19 lbs in).




35. Feed the instrument panel juction block through the H-bracket towards the rear of the car.
36. Slide the IPJB on mounting pads to lock the tabs.
37. Install and tighten IPJB screw.



38. Connect the rear electrical connector to IPJB
39. Tighten the screw.

Tighten
Tighten to 6.5 N·m (5 lbs ft).




40. Install the wiring harness, ground wire and screw to H-bracket.
41. Tighten the screw

Tighten
Tighten to 2.2 N·m (20 lbs in).




42. Install the closeout seal.

Important: Make sure the tabs engage closeout seal holes on both sides

43. Install HVAC control.
44. Install and tighten screws.

Tighten
Tighten to 2.5 N·m (2.2 lbs in).





Install the temperature and mode cables over the pins

Cable Identification:

•	Temperature cable- white

•	Mode cable-black

46. Install cable housings into channel and push down to lock.



47. Connect the blower switch, A/C-Recirc and lighting electrical connectors.

Important: Make sure wiring harnesses do not interfere with control lever movement.




48. Connect the electrical connector and antenna to radio.



49. Install the radio.

Important: Make sure spring clips are seated in D-holes on both sides.

50. Install and tighten the screws.

Tighten
Tighten to 2.5 N·m (22 lbs in).




51. Connect the traction control/fog lamp/rear defog electrical connector, if equipped.
52. Install the radio/HVAC control cover. Push in at clip locations.
53. Install the push pins and lock.



54. Place the shifter in neutral.
55. Lower the front of the console over shifter.
56. Lower the rear of the console over parking brake lever onto rear mounting pad.

Important: Make sure to place window/mirror and ashtray light connectors through openings into position.




57. Move the console rearward.
58. Install the cigarette lighter bulb through opening and rotate counterclockwise.
59. Connect cigarette lighter electrical connector.
60. Move the console forward into position.

Important: Make sure that the upper tabs on front of the console engage sheet metal on lower I/P brace.

61. Install and tighten the front console screws.

Tighten
Tighten to 1.2 N·m (11 lbs in).




62. Install the left and right lower trim panel extensions by inserting hinges into console openings. Then rotate closed and push in at dual lock location.



63. For vehicles without the console armrest:

•	Align the rear of console with pin on mounting pad.

•	Install and tighten screws.

Tighten
Tighten to 1.6 N·m (14 lb in).

•	Install the screw cover.




64. Connect the window/mirror switch electrical connectors.
65. Install the window/mirror switch by inserting front edge into opening. Then push the rear edge down into position.



66. Insert the bulb through the opening until bulb socket is flush with cup holder. Push socket down to engage lock tab.
67. Install the wiring harness to the cup holder.



68. Install the cupholder by inserting through console opening and pushing straight down,



69. Install the parking brake cover over lever.
70. Install and tighten the screw.

Notice: Do not overtighten screw or it may pull through cover.

Tighten
Tighten to 1.6 N·m (14 lbs in).




71. Install the arm rest unit into the console, if equipped. Install and tighten the screws.

Tighten
Tighten to 1.6 N·m (14 lbs in).




72. Install the right and left end cap assemblies.
73. Install and tighten the screws.

Tighten
Tighten to 2.2 N·m (20 lbs in).





Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

74. Raise the vehicle.
75. Install hose and clamp on heater core outlet. Position the clamp at a 7-8 o'clock position



76. Install the hose and clamp on the heater core inlet. Position the clamp at 6 o'clock.



77. Lower the vehicle.
78. Remove the protective covers. Lubricate with R-12 Refrigerant oil (mineral) install new O-rings on evaporator pipes.
79. Install the thermal explosion valve (TXV) on evaporator.

Tighten
Tighten to 10 N·m (89 lbs ft).




80. Lubricate O-rings with R-12 Refrigerant oil (mineral) and install new O-rings on suction hose and liquid line.
81. Insall the liquid line on the TXV.

Tighten
Tighten to 25 N·m (19 lbs ft).

82. Install the suction hose on the TXV.

Tighten
Tighten to 25 N·m (19 lbs ft).




83. Install the air cleaner housing cover and air induction hose.
84. Fill and pressure test the cooling system.
85. Evacuate, charge, and leak test A/C system. Perform A/C Performance Test.
86. Connect the negative battery cable.

Tighten
Tighten to 17 N·m (151 lbs in).

87. Set the clock to proper time if equipped.
88. Enable the SIR system. (Refer to "Enabling the SIR System" in this service manual.)
89. Reset the radio stations.

HVAC Module Assembly Replacement RHDD

1. Disable the SIR system. (Refer to "Disabling the SIR System" in this service manual.)
2. Record the pre-set radio stations.
3. Disconnect the negative battery cable.
4. Recover the refrigerant using an approved refrigerant recovery system.
5. Remove the air cleaner housing cover and air induction hose at the intake manifold.



6. Remove the suction hose and liquid line from the thermal expansion valve.

Notice: Place protective covers over A/C hoses, lines, TXV, and HVAC module to prevent contamination of A/C system.

7. Remove coolant reservoir cap.
8. Drain cooling system.
9. Remove the heater inlet hose from the engine outlet and blow remainder the coolant out of the heater core with an air hose in order to prevent coolant from spilling on the vehicle interior when removing HVAC module.
10. Install the heater inlet hose on the engine outlet and position clamp at 4 o'clock position as viewed from the left side of the vehicle.




Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

11. Raise the vehicle.
12. Move the clamps up the heater core inlet and outlet hoses.



13. Remove the hoses from the heater core



14. Remove for nuts holding lower HVAC module and blower unit to cowl.

•	Left upper side of TXV

•	Lower right side of TXV

•	Left of module drain

•	Lower left side of brake booster

15. Lower the vehicle.



16. Remove nut holding blower unit to cowl at right center of brake booster.



17. Remove the screws and carefully pull right and left end cap assemblies outward at clip locations.



18. Remove the screws and remove the arm rest, if equipped.



19. Lift the parking brake lever.
20. Remove the screw.
21. Remove the parking brake cover by lifting straight off lever.



22. Move the shifter to neutral. Remove the ashtray from the cup holder by lifting straight out.
23. Remove the cup holder from the console by pulling upwards starting at the rear edge.



24. Remove the ashtray bulb socket by lifting tab while sliding socket forward. Then pull socket straight out.
25. Remove the wiring harness from the cup holder.



26. Remove the window/mirror switch, if equipped, by sliding switch forward then lifting at the rear edge. Disconnect the electrical connectors.



27. If the vehicle does not have an arm rest, remove the rear screw cover by lifting at cut out.
28. Remove the rear console screws.



29. Remove left and right lower trim panel extensions by pulling outward at dual lock locations. Then rotate the panels outward to disengage hinges from console.



30. Remove the front console screws.
31. Move console rearward.
32. Disconnect the cigarette lighter electrical connector.
33. Remove the bulb socket from cigarette lighter by rotating clockwise and pulling straight out.



34. Lift the console at rear. Slide the console rearward and lift straight up to remove.



35. Depress the center pins inward to release radio/HVAC controller cover push pins fasteners.

Important: Do not push the center pins through fasteners.

36. Remove the fasteners and pull radio/HVAC controller cover rearward.
37. Disconnect traction control/fog lamp/rear defog electrical connector if equipped.



38. Remove the radio screws.
39. Push the spring clips in through D-holes on both sides of radio brace.
40. Pull the radio out slightly to access the rear of the radio.



41. Disconnect the electrical connector and antenna.
42. Remove the radio.



43. Disconnect blower switch, A/C-Recirc and lighting electrical connectors.



44. Remove the temperature and mode cables from HVAC control by squeezing lock tabs together while pulling cable housing straight up.
45. Remove the cables from pins by pulling straight up. (Service cables shown in illustration.



46. Remove the screws and HVAC controller.



47. Remove the closeout seal by releasing from tabs.



48. Remove the screw and ground wire from H-bracket.
49. Remove the wiring harness from H-bracket.



50. Remove the screw and disconnect the rear electrical connector from the instrument panel block screw.



51. Remove the instrument panel junction block screw.
52. Insert a small flat blade screwdriver from passenger side, to release lock tabs on the instrument panel junction block and slide off of mounting pads.
53. Feed the instrument panel junction block through H-brackets towards the front of the car.



54. Remove the bolts from H-Bracket.



55. Remove the screws from the data link connector(DLC) and steering column filer panel.



56. Lower steering column filler panel and remove hood release handle assembly.
57. Route hood release handle assembly forward through the I/P carrier to the cowl.



58. Disconnect the ignition switch electrical connector at the right steering column bolt.
59. Remove the steering column bolts and the lower column on the front seat.



60. Remove the fasteners and pull the instrument cluster trim bezel rearward at clip locations.
61. Disconnect the electrical connector from the instrument panel dimmer switch.



62. Remove the connector position assurance (CPA) devices and disconnect the electrical connectors from the instrument cluster by squeezing the tabs on each side of connector.



63. Remove the front and rear instrument cluster screws.
64. Remove the instrument cluster.



65. Remove the dimmer and defroster switch wiring harness from the instrument panel reinforcement using a screwdriver to remove rosebud retainer. Replace retainer if damaged during removal.
66. Feed connectors through reinforcement towards front of car.



67. Remove the passenger side air bag harness from cross car beam and energy absorber.



68. Remove the glove box door stops by rotating 90 degrees and let door hang down.
69. Remove the screws from the glove box and compartment and striker.
70. Remove the glove box assembly by pulling rearward at the clip locations.



71. Disconnect PCM electrical connectors.



72. Loosen PCM retaining nut and lift PCM upward and remove.



73. Use the illustration to determine fastener location and direction of removal.



74. Remove the nut, screws and instrument panel pad/reinforcement assembly.



75. Detach wiring harness rosebud fastener from rear of HVAC module.



76. Remove wiring harness rosebud fasteners from side of HVAC module.
77. Remove wiring harness rosebud fastener from left module mounting bracket.



78. Remove lower heater duct screws.




Notice: Be careful not to damage foam seal.

79. For Coupes, slide heater duct downward and then left, into passenger side footwell.
80. For Sedans and Wagons, use a flat blade screwdriver to bend the right side heater duct flange outward at cut lines, then slide duct left into passenger side footwell with wiring harness.
81. Remove BTSI cable from heater duct.



82. Remove the screws and center air outlet duct.



83. Remove the screws and unsnap windshield defroster nozzle from the mode valve assembly



84. Remove the defroster nozzle by rotating front of nozzle up and away from the windshield.



85. Disconnect the blower motor resistor connector.



86. Disconnect the blower motor electrical connectors.



87. Remove ABS module from HVAC module by gently pulling outward to disengage hook and loop fastener, and then rearward to disengage alignment pins.
88. Disconnect ABS module electrical connector and remove module.
89. Remove shift lock cable from clamp at front edge of heater pipe cover.



90. Remove HVAC module mounting brackets to beam bolts.



91. Remove blower unit bracket to cowl screw.



92. Disconnect air valve actuator electrical connector.



93. Remove blower unit from vehicle.



94. Remove the HVAC module from the vehicle.



95. Remove TXV from HVAC module.
96. Place protective cover over evaporator pipes to prevent contamination of A/C system.

Notice: Use only R-12 refrigerant oil to lubricate the O-rings. Use of R-134a (PAG) oil will cause premature corrosion of fitting joints. Do not lubricate seal washers.

1. Install TXV to HVAC module.



2. Install the new cowl panel seals on the heater core pipes, case drain, and evaporator block.



3. Install the HVAC module through the cowl.



4. Install HVAC module mounting bracket to beam bolts, but do not tighten.



5. Connect air valve actuator electrical connector.



6. Install blower unit into HVAC module and through cowl.



7. Install blower unit bracket to cowl bolt.

Tighten
Tighten to 2.2 N·m (20 lbs in)




8. Install blower unit to cowl nut at right side of brake booster.

Tighten
Tighten to 5 N·m (44 lbs in)

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

9. Raise vehicle.
10. Install HVAC module and blower unit nuts.

Tighten
Tighten to 5 N·m (44 lbs in)





Important: Be careful not to push hoses onto heater core pipes so far that foam seal is contacted.

11. Install hose and clamp on heater core outlet. Install clamp at 7-8 o'clock position.
12. Install hose and clamp on heater core inlet. Install clamp at 6 o'clock position.
13. Lower vehicle.



14. Tighten HVAC module mounting brackets to beam bolts.

Tighten
Tighten to 6 N·m (53 lbs in)




15. Connect the blower motor electrical connector.



16. Connect ABS module electrical connector.
17. Install ABS module alignment pins into HVAC module flange and rotate ABS module toward HVAC module to engage hook and loop retainer.
18. Install park lock cable into clamp at forward edge of heater pipe cover.



19. Connect the blower motor resistor electrical connector.



20. Install windshield defroster nozzle onto HVAC module and install screws. Make sure the duct is snapped on both sides of HVAC module.

Tighten
Tighten to 2.2 N·m (20 lbs in)




21. Install the center air outlet duct and screws.

Tighten
Tighten to 10 N·m (89 lbs in).




22. Install brake transaxle interrupt cable into heater duct clamp.

Notice: Be careful not to damage foam seal.

23. Install heater duct to HVAC module.

For Coupes, slide duct under HVAC module from left side and raisee into installed position. Install heater duct screws.




24. Install heater duct to HVAC module.

For Sedans/Wagons cut right heater duct flange off as shown, and slide duct into position between HVAC module and rear seat heater duct. Install left heater duct screw.




25. Install wiring harness rosebud fastener at rear of HVAC module.



26. Install wiring harness fastener into side of HVAC module.
27. Install wiring harness fastener into left HVAC module bracket.



28. Place instrument panel junction block in position.

Important: Make sure PSIR connector harness is on top of beam.

29. Install the instrument panel pad/reinforcement assembly.
30. Install and tighten the nut and bolts.

Tighten
Tighten to 10 N·m(89 lbs in).




31. Install PCM into mounting bracket and tighten nut.

Tighten
Tighten to 10 N·m(89 lbs in).




32. Connect PCM electrical connectors.



33. Install the passenger side air bag harness to energy absorber and cross-car beam



34. Install the dimmer switch and defroster switch wiring harness to instrument panel reinforcement.



35. Install the instument cluster.
36. Install and tighten the screws.

Tighten
Tighten to 3 N·m (26 lbs in).




37. Connect the electrical connectors to the instrument cluster.
38. Install the CPA.



39. Connect the electrical connector to the dimmer switch.
40. Install the instrument cluster trim bezel. Push in at the clip locations.
41. Install the push pin fasteners.



42. Raise the steering column into position.
43. Install and tighten the bolts.

Tighten
Tighten the 35 N·m (26 lbs ft).




44. Route the hood release handle assembly through I/P and then install steering column filler panel.

Tighten
Tighten to 1.5 N·m (13 lbs in).




45. Install the steering column filler panel and DLC.
46. Install and tighten the screws.

Tighten
Tighten to 2.2 N·m (20 lbs in).




47. Install and tighten bolts into H-bracket.

Tighten
Tighten bolts to 25 N·m (19 lbs in).




48. Feed the instrument panel juction block through the H-bracket towards the rear of the car.
49. Slide the IPJB on mounting pads to lock the tabs.
50. Install and tighten IPJB screw.



51. Connect the rear electrical connector to IPJB
52. Tighten the screw.

Tighten
Tighten to 6.5 N·m (5 lbs ft).




53. Install the wiring harness, ground wire and screw to H-bracket.
54. Tighten the screw

Tighten
Tighten to 2.2 N·m (20 lbs in).




55. Install the closeout seal.

Important: Make sure the tabs engage closeout seal holes on both sides




56. Install HVAC control.
57. Install and tighten screws.

Tighten
Tighten to 2.5 N·m (2.2 lbs in).





Install the temperature and mode cables over the pins

Cable Identification:

•	Temperature cable- white

•	Mode cable-black

59. Install cable housings into channel and push down to lock.



60. Place HVAC control mode lever completely to the right-defroster position.



61. Verify that mode cam is still in full counterclockwise position.
62. Press mode cable housing firmly into retainer clip to lock.
63. Move HVAC control mode lever through modes to verify proper installation.



64. Place HVAC control temperature lever completely to the right - full hot.



65. Verify that temperature cam is still in full counterclocwise position.
66. Press temperature cable housing firmly into retainer clip to lock.
67. Move HVAC control temperature lever from hot to cold to verify proper installation.



68. Connect the blower switch, A/C-Recirc and lighting electrical connectors.

Important: Make sure wiring harnesses do not interfere with control lever movement.




69. Connect the electrical connector and antenna to radio.



70. Install the radio.

Important: Make sure spring clips are seated in D-holes on both sides.

71. Install and tighten the screws.

Tighten
Tighten to 2.5 N·m (22 lbs in).

72. Connect the traction control/fog lamp/rear defog electrical connector, if equipped.
73. Install the radio/HVAC control cover. Push in at clip locations.
74. Install the push pins and lock.



75. Install glove box and snap in at clip locations.
76. Install and torqe screws.

Tighten
Tighten to 2.2 N·m (20 lbs in).

77. Install glove box door stops.
78. Adjust striker as necessary.



79. Place the shifter in neutral.
80. Lower the front of the console over shifter.
81. Lower the rear of the console over parking brake lever onto rear mounting pad.

Important: Make sure to place window/mirror and ashtray light connectors through openings into position.




82. Move the console rearward.
83. Install the cigarette lighter bulb through opening and rotate counterclockwise.
84. Connect cigarette lighter electrical connector.
85. Move the console forward into position.

Important: Make sure that the upper tabs on front of the console engage sheet metal on lower I/P brace.

86. Install and tighten the front console screws.

Tighten
Tighten to 1.2 N·m (11 lbs in).




87. Install the left and right lower trim panel extensions by inserting hinges into console openings. Then rotate closed and push in at dual lock location.



88. For vehicles without the console armrest:

•	Align the rear of console with pin on mounting pad.

•	Install and tighten screws.

Tighten
Tighten to 1.6 N·m (14 lb in).

•	Install the screw cover.




89. Connect the window/mirror switch electrical connectors.
90. Install the window/mirror switch by inserting front edge into opening. Then push the rear edge down into position.



91. Insert the bulb through the opening until bulb socket is flush with cup holder. Push socket down to engage lock tab.
92. Install the wiring harness to the cup holder.



93. Install the cupholder by inserting through console opening and pushing straight down,



94. Install the parking brake cover over lever.
95. Install and tighten the screw.

Notice: Do not overtighten screw or it may pull through cover.

Tighten
Tighten to 1.6 N·m (14 lbs in).




96. Install the arm rest unit into the console, if equipped. Install and tighten the screws.

Tighten
Tighten to 1.6 N·m (14 lbs in).




97. Install the right and left end cap assemblies.
98. Install and tighten the screws.

Tighten
Tighten to 2.2 N·m (20 lbs in).




99. Lubricate O-rings with R-12 Refrigerant oil (mineral) and install new O-rings on suction hose and liquid line.
100. Insall the liquid line on the TXV.

Tighten
Tighten to 25 N·m (19 lbs ft).

101. Install the suction hose on the TXV.

Tighten
Tighten to 25 N·m (19 lbs ft).




102. Install the air cleaner housing cover and air induction hose.
103. Fill and pressure test the cooling system.
104. Evacuate, charge, and leak test A/C system. Perform A/C Performance Test.
105. Connect the negative battery cable.

Tighten
Tighten to 17 N·m (151 lbs in).

106. Set the clock to proper time if equipped.
107. Enable the SIR system. (Refer to "Enabling the SIR System" in this service manual.)
108. Reset the radio stations.

HVAC Module Assembly Replacement RHDD Bench Overhaul

1. Remove the pipe cover screws and remove the pipe cover.



2. Remove the pipe support plate screws and remove the support plate.




Important: Be careful not to spill any residual coolant from the heater core when removing.

3. Remove the heater core assembly from the module case.



4. Remove the left module mounting bracket screws and remove the mounting bracket.



5. Release the temperature cable from the retainer clip by pushing upward on the upper tab of the clip while pulling outward on the cable housing.



6. Remove the temperature cable circular push-on retainer.
7. Remove the temperature cable from the temperature cam.



8. Use a small flat-bladed screwdriver to gently pry back the upper mix lever center tab and pull the upper mix lever off the shaft.



9. Remove the temperature cam screw and washer and remove the cam.



10. Use a small flat-bladed screwdriver to gently pry back the lower mix lever center tab and pull the lower lever off the shaft.



11. Remove the mode cable from the retainer clip by pressing upward on the upper tab while pulling outward on the cable housing.



12. Remove the mode cam screw and washer and pull the cam outward to disengage the mode cable eyelet.



13. Remove the defroster door sub-lever screw and washer and remove the lever.



14. Remove the heater door sub-lever screw and washer and remove the lever.



15. Using a small flat-bladed screwdriver, gently pry back center tabs and pull the defroster lever, vent lever, and heater lever off of the shaft.



16. Remove the lower case screws and remove the lower case.



17. Use a razor blade to carefully cut the defroster and vent foam seals at the centerline.




Important: One screw is located in the deep cavity to the right of the mix cam.

18. Remove the case screws and lift straight up to separate the 2 halves of the case.



19. Remove the evaporator core.

Important: When installing a new evaporator core, 67 ml (2.25 oz) of PAG oil must be added to the core. Replace the evaporator pipe cover before installing core.

1. Install the evaporator core into the right side or the HVAC module case.




Important: 

•	Left case half cross support must interlock with right case half cross support.

•	When properly seated, module case tongue and groove seal will fit together snugly.

2. Install the left half of the HVAC module case cover core and align the door shafts with the openings. Press the halves together until seated.



3. Install the case screws. When installing center screw, use a piece of tape to hold the screw to the socket until the threads are started.




Important: When properly seated, module case tongue and groove seal will fit together snugly.

4. Install the lower case.
5. Install the lower case screws.



6. Install the heater core assembly. Press the core into the HVAC module case until the pipes contact the pipe cover attachment boss.



7. Install the heater core pipe cover and screws.




Important: All plastic cam levers have molded in part names and numbers. Refer to the cam illustration chart for part location information. All levers must be installed with the retention tang outward. Applying pressure to the opposite end of the door shaft may aid in seating the tang into the shaft.

8. Install the defroster lever labeled DEF onto the defroster door shaft until the tang seats into the shaft notch.
9. Install the vent lever labeled VENT 1301 onto the vent door shaft until the tang seats into the shaft notch.
10. Install the heater lever labeled VENT 1401 onto the heater door shaft until the tang seats into the shaft notch.



11. Position the metal heater sub-lever on the module boss with the pin set into the heater door lever.
12. Install the heater sub-lever washer and screw.
13. Rotate the heater sub-lever to verify the smooth operation of the levers and heater door.



14. Position the metal defroster sub-lever on the module boss with the pins set into the defroster door lever.
15. Install the defroster sub-lever washer and screw.
16. Rotate the defroster sub-lever to verify the smooth operation of the lever and defroster door.



17. Install the mode cam on the center boss. Align the defroster sub-lever, vent lever, and heater sub-lever so that each pin is the proper mode cam track.
18. Install the mode cam washer and screw.
19. Rotate the mode cam to verify the smooth operation of all doors, levers, and sub-levers.




Important: Install the mode cable with the wire eyelet wrap as shown.

20. Install the mode cable.




Important: Do not install the mode cable housing into the retainer at this time.

21. Install the mode cable eyelet between the mode cam pin and module case and rotate onto the mode cam pin.



22. Install the lever labeled HOT onto the lower mix cam door shaft until the tang seats into the shaft notch.



23. Install the temperature cam ensuring that the lower mix lever pin is in the cam lower track.
24. Install the temperature cam washer and screw.



25. Position the lever labeled COOL onto the upper mix cam door shaft so that the pin will be in the upper temperature cam track when seated. Press down until the tang seats into the shaft notch.
26. Rotate the temperature cam to verify the smooth operation of both doors.




Important: Install the temperature cable with the wire eyelet wrap as shown.

27. Install the temperature cable.




Important: Do not install the temperature cable housing into the retainer at this time.

28. Install the temperature cable on the temperature cam pin and install the circular push-on retainer.



29. Install the left module mounting bracket and screws.



30. Install the pipe support plate screws.




Important: The heater core pipe seal consists of 2 seals installed back-to-back.

31. Install the evaporator block seal, heater core pipe seal, and drain tube seal.