Tools Required

Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front end.



5. Remove the accumulator tube to evaporator core block fitting bolt.
6. Disconnect the accumulator tube from the evaporator.
7. Disconnect the evaporator tube from the evaporator.
8. Remove the O-rings seals and discard.



9. UseJ 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
10. Disconnect the inlet and outlet heater hose from the heater core.
11. Remove the IP lower trim panel. Refer to Instrument Panel Lower Trim Panel Replacement in Instrument Panel, Gages, and Console.



12. Remove the retaining screw (1) from the panel sir duct.
13. Remove the retaining bolts from the panel air duct.
14. Remove the panel air duct from the cross vehicle beam.



15. Remove the retaining bolts from the right air duct.
16. Remove the right air duct from the cross vehicle beam.
17. Remove the steering column. Refer to Steering Column Replacement in Steering Wheel and Column.
18. Disconnect the left side fuse block from the cross vehicle beam.
19. Remove the passenger knee bolster bracket. Refer to Passenger Knee Bolster Bracket Replacement in Instrument Panel, Gages, and Console.
20. Position the body control module away from the cross vehicle beam.
21. Remove the brake pedal. Refer to Brake Pedal Replacement in Hydraulic Brakes.
22. Remove the three brake pedal brace bolts from the cross vehicle beam.
23. Disconnect any ground wires, as necessary.
24. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.



25. Remove the bolts from the HVAC module center support.
26. Remove the bracket from the HVAC module center support
27. Reposition the vacuum harness.



28. Remove the bracket bolts from the HVAC module upper support.



29. Remove the bolts from the right and left side of the cross vehicle beam.



30. Remove the cross vehicle beam.
31. Disconnect the vacuum hoses from the HVAC control module.
32. Disconnect the electrical connectors from the HVAC control module.



33. Remove the evaporator drain elbow.



34. Remove the nuts which secure the HVAC control module to the dash.
35. Remove the HVAC control module:

35.1.

Pull the HVAC control module rearward to disengage the mounting studs from the dash panel.

35.2.

Position aside the dash insulator pad from the recirculation opening of the HVAC control module .

35.3.

Roll the HVAC control module downward and rearward to disconnect the heater core outlet cover from the rear floor air outlet duct.

35.4.

Remove the HVAC control module.




36. Remove and discard all of the seals (1,2,3) from the outer HVAC control module.

1. Install new seals (1,2,3) to the outer HVAC control module.

Important:  When installing the HVAC control module, ensure that the dash insulator pad cut-outs and the HVAC seals, studs, and drain align and seal properly to the dash panel.

2. Install the HVAC control module into the vehicle:

2.1.	Align the heater core outlet cover to the rear floor air outlet duct.

2.2.	Roll the HVAC control module forward and upward and align the dash insulator pad to the recirculation opening of the HVAC control module.

2.3.	Align the mounting studs and the drain on the HVAC control module to seat against the dash panel.





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 control module to the dash.

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




4. Install the evaporator drain elbow.
5. Connect the vacuum hoses to the HVAC control module.
6. Connect the electrical connectors to the HVAC control module.



7. Install the cross vehicle beam to the vehicle



8. Install the bolts to the right and left side of the cross vehicle beam.
9. Tighten the bolts to the right and left side of the cross vehicle beam in sequence.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




10. Install the bracket bolts to the HVAC module upper support.

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

11. Install the passenger knee bolster bracket. Refer to Passenger Knee Bolster Bracket Replacement in Instrument Panel, Gages, and Console.



12. Install the bracket to the HVAC module center support.
13. Install the bolts to the HVAC module center support.
14. Reposition the vacuum harness to the original position.
15. Tighten the bolts in sequence as shown.

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

16. Reposition the IP wiring harness on to the cross vehicle beam and secure the retaining clips.
17. Connect all disconnected ground wires.
18. Install the three brake pedal brace bolts.

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

19. Install the brake pedal. Refer to Brake Pedal Replacement in Hydraulic Brakes.
20. Install the body control module.
21. Install the left side fuse block to the cross vehicle beam.
22. Install the steering column. Refer to Steering Column Replacement in Steering Wheel and Column.



23. Install the right air duct to the cross vehicle beam.
24. Install the right air duct bolts.

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




25. Install the panel air duct to the cross vehicle beam.
26. Install the panel air duct screw (1).

Tighten
Tighten the screw to 1.8 N·m (16 lb in).

27. Install the panel air duct bolts.

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

28. Install the IP lower trim panel. Refer to Instrument Panel Lower Trim Panel Replacement in Instrument Panel, Gages, and Console.



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

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

30. UseJ 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.
31. Install new O-rings seals on the evaporator tube and accumulator tube. Refer to O-Ring Replacement .



32. Connect the evaporator tube to the evaporator.
33. Connect the accumulator tube to the evaporator.
34. Install the accumulator tube to evaporator core block fitting bolt.

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

35. Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
36. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
37. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
38. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
39. Leak test the fittings of the component using J 39400-A .