Tools Required

J 39400-A Halogen Leak Detector

1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Remove the nuts connecting the evaporator lines to the evaporator.
4. Remove the evaporator lines from the evaporator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Disconnect the heater hoses from the heater core. Refer to Heater Inlet Hose Replacement and to Heater Outlet Hose Replacement .
7. Lower the vehicle.
8. Remove the evaporator case drain tube. Refer to Evaporator Tube Replacement .
9. Remove the IP carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages and Console.



10. Disconnect the wiring harness from the cross vehicle beam (1).
11. Remove the attaching bolts from the right and left side of the HVAC module.
12. Remove the bolts (2) from the cross vehicle beam.

Important: Place the steering column in the straight tilt position using the tilt lever.

13. Remove the cross vehicle beam (1) from the front of the vehicle.
14. Remove the floor air outlet. Refer to Floor Air Outlet Replacement .
15. Disconnect the wiring harness from the HVAC module assembly.
16. Disconnect the electrical connections at the following locations:

•	The blower motor

•	The blower resistor

17. Remove the HVAC module attaching bolts near the heater hoses and the A/C evaporator lines.



18. Remove the HVAC module assembly screw (2) from the mounting bracket (1).



19. Disconnect the gray source vacuum line (1).

Important: Do NOT tilt the HVAC module assembly, or coolant may leak out.

20. Remove the module from the vehicle.

1. Install the HVAC module assembly. Align the mounting bracket (1) to the hole. Install the screw (2) to the mounting bracket.

Tighten
Tighten the bolt to 2 N·m (18 lb in).

2. Install the HVAC module attaching bolts near the heater hoses and the A/C evaporator lines.

Tighten
Tighten the bolts to 2 N·m (18 lb in).




3. Connect the gray vacuum line (1).
4. Connect the electrical connections at the following locations:

•	The blower motor

•	The blower resistors

5. Connect the wiring harness to the HVAC module assembly.
6. Install the floor air outlet. Refer to Floor Air Outlet Replacement .



7. Install the cross vehicle beam (1) to the front of the dash.

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.

8. Install the bolts (2) and the studs (3) to the cross vehicle beam (1).

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

9. Install the support bolts on the right and left side of the HVAC module.

Tighten
Tighten the fittings to 2 N·m (18 lb in).

10. Connect the wiring harness to the cross vehicle beam (1).
11. Install the IP carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages and Console.
12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
13. Install the evaporator case drain tube. Refer to Evaporator Tube Replacement .
14. Connect the heater hoses to the heater core. Refer to Heater Inlet Hose Replacement and to Heater Outlet Hose Replacement .
15. Lower the vehicle.
16. Connect the evaporator tubes to the evaporator.

Tighten
Tighten the fittings to 24 N·m (18 lb ft).

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