Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Remove the left wiper arm linkage nuts.

Reposition the left wiper arm linkage for access.

Important: The defroster door must be closed to allow clearance during defroster duct removal.

4. Set the HVAC controls in the vent setting to close the defroster door.
5. Remove the blower motor. Refer to Blower Motor Replacement .



6. Disconnect the electrical connector from the blower motor resistor.



7. Disconnect the electrical connector from the evaporator temperature sensor.
8. Disconnect all of the HVAC actuator electrical connectors.
9. Remove the IP carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages and Console.



10. Remove the evaporator outlet tube nut.
11. Disconnect the evaporator outlet tube and evaporator inlet tube from the TXV.
12. Remove the heater inlet hose from the heater core. Refer to Heater Inlet Hose Replacement .
13. Remove the heater outlet hose from the heater core. Refer to Heater Outlet Hose Replacement .



14. Remove the HVAC module to dash panel sound barrier nuts.
15. Remove the HVAC module assembly from the cowl.

Important: Ensure proper alignment of the HVAC module assembly and HVAC module drain tube through the cowl.

1. Install the HVAC module assembly to the cowl.



2. Install the HVAC module assembly to dash panel sound barrier nuts.

Do not tighten the HVAC module assembly nuts at this time.

3. Install the heater outlet hose to the heater core. Refer to Heater Outlet Hose Replacement .
4. Install the heater inlet hose to the heater core. Refer to Heater Inlet Hose Replacement .
5. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the evaporator tubes and TXV.

Important: Flat washer type seals do not require lubrication.

6. Install the new sealing washers.
7. Connect the evaporator inlet tube to the evaporator outlet tube.
8. Connect the evaporator inlet and outlet tubes to the TXV.




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 evaporator outlet tube nut at the TXV.

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

10. Install the IP carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages and Console.
11. Connect all of the HVAC actuator electrical connectors.



12. Connect the electrical connector to the evaporator temperature sensor.



13. Connect the electrical connector to the blower motor resistor.
14. Install the blower motor. Refer to Blower Motor Replacement .



15. Tighten the HVAC module assembly to dash panel sound barrier nuts.

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

16. Install the left wiper arm linkage.
17. Install the left wiper arm linkage nuts.

Tighten
Tighten the nuts to 5 N·m (44 lb in).

18. Fill the coolant system. Refer to Cooling System Draining and Filling in Engine Cooling.
19. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
20. Leak test the fittings of the component using the J 39400-A .