For 1990-2009 cars

#### Special Tools

J 39400-A Halogen Leak Detector

### Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Drain the coolant. Refer to Cooling System Draining and Filling .
3. Disconnect the heater inlet hose from the heater core. Refer to Heater Inlet Hose Replacement .
4. Disconnect the heater outlet hose from the heater core. Refer to Heater Outlet Hose Replacement .
5. At the evaporator core, disconnect and remove the A/C quick connect fittings from the suction hose and the liquid line. Refer to Air Conditioning Line/Tube Connector Removal/Replacement .
6. Separate the suction hose and liquid line from the evaporator core.
7. Remove and discard the O-rings.
8. Remove the instrument panel (I/P) carrier. Refer to Instrument Panel Carrier Replacement .
9. Remove the blower and air inlet assembly.
10. Disconnect the HVAC module electrical connector.
11. Disconnect the HVAC module drain tube (2) from the floor.
12. Remove the lower left HVAC module mounting nut (1).
13. Remove the upper left HVAC module mounting nut (1).
14. Remove the HVAC module from the vehicle.
15. Remove the foam from the A/C lines.
16. Remove the foam from around the heater pipes.

### Installation Procedure

1. Install the thick foam packing (1) on the heater core pipes.
2. Install the thin foam packing (2) on the heater core pipes.
3. Install the thick foam packing (1) on the A/C lines.
4. Install the thin foam packing (2) on the A/C lines.
5. Install the HVAC module into the vehicle.

Notice: Refer to Fastener Notice in the Preface section.

6. Install the upper left HVAC module mounting nut (1).

Tighten
Tighten the nut to 9 N·m (80 lb in).

7. Install the lower left HVAC module mounting nut (1).

Tighten
Tighten the nut to 9 N·m (80 lb in).

8. Connect the drain tube to the bottom of the HVAC module.
9. Connect the drain tube (2) to the floor.
10. Connect the HVAC electrical connector.
11. Install the air inlet assembly.
12. Install the I/P carrier. Refer to Instrument Panel Carrier Replacement .
13. Install new O-rings to the suction hose and liquid line. Refer to O-Ring Replacement .
14. Connect the suction hose and liquid line to the evaporator core.
15. Install the A/C quick connect fittings to the suction hose and liquid line. Refer to Air Conditioning Line/Tube Connector Removal/Replacement .
16. Connect the heater inlet hose to the heater core. Refer to Heater Inlet Hose Replacement .
17. Connect the heater outlet hose to the heater core. Refer to Heater Outlet Hose Replacement .
18. Fill the coolant. Refer to Cooling System Draining and Filling .
19. Evacuate and recharge the AC system. Refer to Refrigerant Recovery and Recharging .
20. Leak test the fittings of the component using J 39400-A .