Tools Required

J 39400-A Halogen Leak Detector

1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
2. Disconnect the vacuum harness from both of the harness retainers on the HVAC module case.



3. Disconnect the vacuum harness connectors from the defroster actuator.
4. Rotate the defrost door lever fully rearward (counterclockwise), then carefully insert a flat bladed tool between the bottom of the defrost door lever and the protruding wall of the HVAC module case below the door lever in order to keep the door lever in place.



5. Lift to release the defroster actuator retaining tab.



6. Disconnect the defroster actuator pushrod from the defrost door lever and remove the actuator.



7. Remove the screws retaining the HVAC module case - upper to the HVAC module case - lower.

To access the screw hidden under the air inlet door, open the door and retain in the open position.

8. Release the retaining tab (1) securing the HVAC module case - upper to the HVAC module case - lower.
9. Separate the HVAC module case - upper from the HVAC module case - lower.



10. Remove and discard the HVAC module case seals.

Start to remove the HVAC module case primary (blower motor side of case) seal (2) from the HVAC module case - lower at the position shown (1).




11. Remove the evaporator core from the HVAC module case - lower.

1. If installing a new evaporator core, add the specified amount of PAG Refer to Refrigerant System Capacities .



2. Install a new water core filter to the evaporator core.



3. Install a new side seal to the evaporator core.

Line the evaporator core side seal up with the corners of the evaporator core.




4. Install a new upper seal to the evaporator core.



5. Install two new lower seals to the evaporator core.

Locate the seals at the outer corners (or edges) of the evaporator core.




6. Install the evaporator core to the HVAC module case - lower.



7. Install new case seals to the HVAC module case - lower.

Start to install the HVAC module case primary (blower motor side of case) seal (2) to the HVAC module case - lower from the position shown (1).





Important: Inspect the condition of the retaining tab on the HVAC module case - upper prior to installing to the HVAC module case - upper to the HVAC module case - lower. If the retaining tab is broken or damaged, install an external retaining clip.

8. Align and install the HVAC module case - upper to the HVAC module case - lower.

Align and secure the retaining tab (1) on the HVAC module case - upper to the retaining slot on the HVAC module case - lower.

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.

9. Install the HVAC module case - upper to the HVAC module case - lower retaining screws.

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




10. Connect the defroster actuator pushrod to the defrost door lever.



11. Position the defroster actuator in line with the mounting pins on the HVAC module case.
12. Carefully rotate the defroster actuator until the actuator slots align with the HVAC module mounting pins.
13. Inspect that the defroster actuator pushrod is not binding on the defrost door lever.
14. Push the defroster actuator toward the HVAC module case to secure the retaining tab.



15. Remove the flat bladed tool maintaining the defrost door lever in position.
16. Connect both of the vacuum harness connectors to the defroster actuator.
17. Secure the vacuum harness to both of the harness retainers on the HVAC module case.
18. Install the HVAC module to the vehicle. Refer to HVAC Module Assembly Replacement .