Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Remove the battery heat shield. Refer to Battery Heat Shield Replacement in Engine Electrical.
3. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical 5.7-L.
4. Disconnect the hose clamp and hose from the RH air injection check valve. If equipped



5. Remove the RH air injection check valve to LH cylinder head bolt. If equipped
6. Remove the RH air injection check valve to RH cylinder head bolts. If equipped
7. Remove the RH air injection pipe. If equipped



8. Remove the nut retaining the heater pipe bracket to the cowl.
9. Reposition the heater pipe bracket.



10. Remove the heater pipe to heater core retaining bolt.

Important: Cap or plug the open heater pipe assembly and the heater core to prevent system contamination.

11. Disconnect the heater pipe assembly from the heater core.

•	Allow any remaining coolant to drain

•	Remove and discard the sealing washers

•	Cap or plug the heater pipe assembly and the heater core to prevent contamination




12. Remove the accumulator hose to evaporator retaining bolt.

Important: Cap or tape the A/C components immediately to prevent system contamination.

13. Disconnect the accumulator hose and the evaporator tube - rear from the evaporator.

•	Discard the O-ring seals

•	Cap or tape the hose end, the tube end and the evaporator to prevent contamination.




14. Remove the HVAC module drain tube from the HVAC module.
15. Remove the I/P upper trim pad. Refer to Instrument Panel Upper Trim Pad Replacement in Instrument Panel, Gages and Console.



16. Remove the LH side window defogger outlet duct - lower.

16.1.

Remove the push-in retainer.

16.2.

Use a twisting motion to release the defogger outlet duct - lower from the windshield defroster duct, then from the defogger outlet duct - upper.




17. Remove the inside air temperature sensor aspirator duct.

17.1.

Depress the duct retaining tab and remove the duct from the ignition switch housing bracket.

17.2.

Use a twisting motion to release the duct from the duct muffler.




18. Disconnect the DRL sensor electrical connector, if equipped.



19. Disconnect the electrical connector from the LH temperature actuator.



20. Remove the I/P center support bracket and the ignition switch housing bracket. Refer to Instrument Panel Center Support Bracket Replacement in Instrument Panel, Gages and Console.
21. Remove the LH floor air outlet duct retaining screws.
22. Remove the LH floor air outlet duct.



23. Remove the LH floor air outlet duct - rear.

Rotate the duct 1/4 turn clockwise to release.




24. Remove the RH side window defogger outlet duct - lower.

24.1.

Depress the defogger outlet duct - lower retaining tabs and release the duct from the passenger SIR bracket.

24.2.

Use a twisting motion to release the defogger outlet duct - lower from the windshield defroster duct, then from the defogger outlet duct - upper.

25. Remove the passenger SIR bracket and the passenger knee bolster bracket. Refer to Knee Bolster Bracket Replacement in Instrument Panel, Gages and Console.
26. Disconnect the sunload sensor electrical connector.



27. Disconnect the electrical connector from the RH temperature actuator.



28. Remove the RH floor air outlet duct retaining screws.
29. Remove the RH floor air outlet duct.



30. Reposition the carpet away from the RH side of the driveline tunnel to access the carpet air outlet duct.
31. Use a rotating motion the release the carpet air outlet duct from the floor air outlet duct - rear.



32. Remove the RH floor air outlet duct - rear.

Rotate the duct - rear 1/4 turn counterclockwise to release.




33. Disconnect the electrical connector from the blower motor control module.
34. Remove the blower motor. Refer to Blower Motor Replacement .



35. Disconnect the I/P harness vacuum supply line (1) from the HVAC module vacuum harness (2).



36. Disconnect the electrical connector from the vacuum electric solenoid.



37. Remove the windshield defroster duct retaining screws.
38. Remove the windshield defroster duct.



39. Remove the HVAC module retaining and sealing nuts from the cowl.

Reposition the refrigerant lines slightly, if necessary.

40. Remove the HVAC module retaining bolts from the I/P upper support beam.
41. Carefully remove the HVAC module from the vehicle.



42. Remove and discard the HVAC module air inlet, drain and plumbing seals.

1. Install new air inlet, drain and plumbing seals to the HVAC module.



2. Carefully install the HVAC module to the vehicle in the following SEQUENCE.

Important: Ensure that the cut-outs on the dash mat are properly aligned so that the air inlet, drain, and plumbing seals are seated directly against the cowl and not the dashmat.

2.1.	Inspect the dashmat (1) for proper alignment to the cowl. Align if necessary.

The opening in the dashmat for the HVAC module drain should be aligned so that the drain opening in the cowl is approximately centered in the dash mat opening; allowing ample room for the module drain seal (2) to fully seat against the cowl.

2.2.	ALIGN the heater core joint fitting, the condenser joint fitting, the HVAC module drain and the HVAC module studs to the corresponding openings on the cowl.

2.3.	INSERT the LH stud into the cowl FIRST, then the module drain, then the RH stud.

2.4.	Install the HVAC module LH retaining bolt to the I/P upper support beam module net locating hole (3).

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.

2.5.	Install the HVAC module RH retaining bolt to the I/P upper support beam.

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

Important: To prevent possible water leaks or wind/road noise from entering the vehicle passenger compartment, DO NOT reuse the old HVAC module retaining and sealing nuts.

2.6.	Install the HVAC module new retaining and sealing nuts.

2.7.	Tighten the HVAC module retaining and sealing nuts.

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




3. Install and align the windshield defroster duct to the HVAC module opening and the I/P upper support beam.
4. Install the windshield defroster duct LH retaining screw (net locating hole).
5. Install the windshield defroster duct RH retaining screw.

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




6. Connect the electrical connector to the vacuum electric solenoid.



7. Connect the I/P harness vacuum supply line (1) to the HVAC module vacuum harness (2).



8. Install the blower motor. Refer to Blower Motor Replacement .
9. Connect the electrical connector to the blower motor control module.



10. Position and align the RH floor air outlet duct - rear to the HVAC module, then push firmly and evenly to secure the duct.



11. Secure the carpet air outlet duct to the RH floor air outlet duct - rear.

Use a rotating motion to secure the carpet air outlet duct to the floor air outlet duct - rear.

12. Position the front floor carpet to the RH side of the driveline tunnel.



13. Install the RH floor air outlet duct to the HVAC module.
14. Install the RH floor air outlet duct retaining screws.

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




15. Connect the electrical connector to the RH temperature actuator.
16. Connect the sunload sensor electrical connector.



17. Install the passenger SIR bracket and the passenger knee bolster bracket. Refer to Knee Bolster Bracket Replacement in Instrument Panel, Gages and Console.
18. Install the RH side window defogger outlet duct - lower.

18.1.

Use a twisting motion to secure the defogger outlet duct - lower to the defogger outlet duct - upper, then to the windshield defroster duct.

18.2.

Install the defogger outlet duct - lower retaining tabs to the passenger SIR bracket.




19. Position and align the LH floor air outlet duct - rear to the HVAC module, then push firmly and evenly to secure the duct.



20. Install the LH floor air outlet duct to the HVAC module.
21. Install the LH floor air outlet duct retaining screws.

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

22. Install the I/P center support bracket and the ignition switch housing bracket. Refer to Instrument Panel Center Support Bracket Replacement in Instrument Panel, Gages and Console.



23. Connect the electrical connector to the LH temperature actuator.
24. Connect the DRL sensor electrical connector, if equipped.



25. Install the inside air temperature sensor aspirator duct muffler.

Use a twisting motion to secure the duct muffler.




26. Install the inside air temperature sensor aspirator duct.

26.1.

Use a twisting motion to secure the duct to the duct muffler.

26.2.

Install the duct retaining tab to the ignition switch housing bracket.




27. Install the LH side window defogger outlet duct - lower.

27.1.

Use a twisting motion to secure the defogger outlet duct - lower to the defogger outlet duct - upper, then to the windshield defroster duct.

27.2.

Install the push-in retainer.

28. Install the I/P upper trim pad. Refer to Instrument Panel Upper Trim Pad Replacement in Instrument Panel, Gages and Console.



29. Install the HVAC module drain tube to the module.

•	Ensure that the drain tube is fully seated to the HVAC module.

•	Align the drain tube to contact the cowl as shown (1).

30. Remove the cap or tape from the accumulator hose, evaporator tube - rear and the evaporator.
31. Install a new O-ring. Refer to O-Ring Replacement .



32. Install the accumulator hose and evaporator tube - rear to the evaporator.
33. Install the accumulator hose to evaporator retaining bolt.

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




34. Remove the cap or plug from the heater pipe assembly and the heater core.
35. Install new sealing washers. Refer to Sealing Washer Replacement .
36. Connect the heater pipe assembly to the heater core.
37. Install the heater pipe assembly retaining bolt.

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

38. Install the RH air injection pipe.
39. Install the RH air injection pipe to RH cylinder head bolts.

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




40. Install the RH air injection check valve to LH cylinder head bolt.

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

41. Connect the hose and hose clamp to the RH air injection check valve.



42. Install the heater pipe bracket into position.
43. Install the heater pipe bracket retaining nut.

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

44. Install the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical 5.7-L.
45. Install the battery heat shield. Refer to Battery Heat Shield Replacement in Engine Electrical.
46. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
47. Leak test the fittings of the component using J 39400-A .