Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. 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 sheet metal diagonal brace. Refer to Front End Sheet Metal Diagonal Brace Replacement in Body Front End.
4. Disconnect the A/C lines at the evaporator. Refer to Evaporator Tube Replacement .
5. Disconnect the heater hoses at the heater core. Refer to Heater Hoses Replacement .
6. Remove the trim pad from the instrument panel. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gauges and Console.
7. Remove the cross vehicle beam. Refer to Instrument Panel Tie Bar Replacement in Instrument Panel, Gauges and Console.




Important: Position the heater core cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly.

8. Remove the heater core outlet cover screws.
9. Remove the heater core outlet cover.



10. Remove the evaporator drain elbow.



11. Remove the HVAC module assembly to dash nuts.
12. Disconnect the vacuum hoses.
13. Disconnect the electrical connectors.
14. Remove the HVAC module assembly.



15. Remove all of the outer HVAC module assembly seals (1, 2, 3).

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




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 HVAC module assembly to dash nuts.

Tighten
Tighten the HVAC module assembly to dash nuts to 10 N·m (89 lb in).




4. Install the evaporator drain elbow.
5. Connect the electrical connectors.
6. Connect the vacuum hoses.
7. Install the cross vehicle beam. Refer to Instrument Panel Tie Bar Replacement in Instrument Panel, Gauges and Console.
8. Install the trim pad to the instrument panel. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gauges and Console.
9. Connect the heater hoses at the heater core. Refer to Heater Hoses Replacement .
10. Install the A/C lines at the evaporator. Refer to Evaporator Tube Replacement .
11. Refill the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
12. Install the left sheet metal diagonal brace. Refer to Front End Sheet Metal Diagonal Brace Replacement in Body Front End.
13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fittings of the component usingJ 39400-A .