Tools Required

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Remove the fuel injector sight shield (3.8L only). Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical-3.8L.
4. Remove the instrument panel trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gages and Console.
5. Remove the passenger side SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
6. Remove the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
7. Disconnect any ground wires, as necessary.
8. Remove the nuts and bolts from the steering column support bracket.
9. Remove the steering column support bracket from the cross vehicle beam.



10. Remove the screws from the right and left side air distribution duct.
11. Remove the right and left side air distribution duct.



12. Remove the bolts from the relay bracket and position the relay bracket aside.



13. Remove the bolts from the BCM bracket and position the BCM bracket aside.
14. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
15. Remove the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam.



16. Remove the bolts from the center support bracket of the HVAC module.
17. Remove the center support bracket of the HVAC module.



18. Remove the bolts from the upper support brackets of the HVAC module.



19. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.



20. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.



21. Remove the bolt (1) from the cross vehicle beam.
22. Remove the cross vehicle beam from the vehicle.



23. Remove the accumulator tube to evaporator core block fitting bolt.
24. Disconnect the accumulator tube from the evaporator.
25. Disconnect the evaporator tube from the evaporator.
26. Remove the O-ring seals and discard.



27. UseJ 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
28. Disconnect the inlet and outlet heater hose from the heater core.




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

29. Remove the screws from the heater core outlet cover.
30. Remove the heater core outlet cover.



31. Remove the evaporator drain elbow.



32. Remove the mounting nuts for the HVAC module assembly from the cowl.
33. Disconnect the vacuum hoses from the HVAC module assembly.
34. Disconnect the electrical connectors from the HVAC module assembly.
35. Remove the HVAC module assembly.



36. 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: 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 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. Connect the vacuum hoses to the HVAC module assembly.



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

Tighten
Tighten the screws to 1.5 N·m (13 lb in).




9. Install the cross vehicle beam to the vehicle.




Important:  Do NOT tighten the bolts at this time.

10. Install the bolts which secure the right cross vehicle beam to the hinge pillar.



11. Install the bolts which secure the left cross vehicle beam to the hinge pillar.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).




12. Install the bolt (1) to the cross vehicle beam.

Tighten
Tighten the bolt to 20 N·m (15 lb ft).




13. Install the bolts to the upper support brackets of the HVAC module.

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




14. Install the center support bracket to the HVAC module.
15. Install the bolts to the center support bracket of the HVAC module.

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

16. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.
17. Install the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam.



18. Install the BCM bracket and the bolts.

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




19. Install the relay bracket and the bolts.

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




20. Install the right and left side air distribution ducts.
21. Install the screws to the right and left side air distribution duct.

Tighten
Tighten the screws to 1.5 N·m (13 lb in).

22. Install the steering column support bracket to the cross vehicle beam.



23. Install the steering column support bracket nuts and bolts.

Tighten
Tighten the nuts and bolts to 50 N·m (37 lb ft).

24. Install the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
25. Connect all disconnected ground wires.
26. Install the passenger side SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
27. Install the instrument panel trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gages and Console.



28. Connect the inlet and outlet heater hose to the heater core.

Important: Reposition the heater core hose clamps in the indicated location.

29. UseJ 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.



30. Connect the evaporator tube to the evaporator.
31. Connect the accumulator tube to the evaporator.
32. Install the accumulator tube to evaporator core block fitting bolt.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

33. Install the fuel injector sight shield (3.8L only). Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical-3.8L.
34. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
35. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
36. Leak test the fittings of the component using J 39400-A .