Install

Installation Procedure





1. Install new air inlet, drain, and plumbing seals to the HVAC module.





2. Carefully install the HVAC module to the vehicle in the following SEQUENCE.

Important: Ensure that the cut-outs on the dashmat are properly aligned so that the air inlet, drain, and plumbing seals are seated directly against the dash panel and not the dashmat.

2.1. Check the dashmat (1) for proper alignment to the dash panel; align if necessary.
The opening in the dashmat for the HVAC module drain should be aligned so that the drain opening in the dash panel is approximately centered in the dash mat opening; allowing ample room for the module drain seal (2) to fully seat against the dash panel.
2.2. ALIGN the heater core joint fitting, the condenser joint fitting, the HVAC module drain and the HVAC module studs to the corresponding openings on the dash panel.
2.3. INSERT the LH stud into the dash panel FIRST, then the module drain, then the RH stud.
2.4. Install the HVAC module LH retaining bolt to the I/P upper support beam module net locating hole (3).
2.5. Install the HVAC module RH retaining bolt to the I/P upper support beam.

Tighten
Tighten the HVAC module retaining bolts to 10 N.m (89 lb in).

Important: To prevent possible water leaks or wind/road noise from entering the vehicle passenger compartment, DO NOT reuse the old HVAC module retaining and sealing nuts.

2.6. Install the HVAC module new retaining and sealing nuts to the dash panel. Reposition the refrigerant lines slightly, if necessary.

Tighten
Tighten the HVAC module retaining and sealing nuts to 10 N.m (89 lb in).





3. Install and align the windshield defroster duct to the HVAC module opening and the lip upper support beam.
4. Install the windshield defroster duct LH retaining screw (net locating hole).
5. Install the windshield defroster duct RH retaining screw.

Tighten
Tighten the windshield defroster duct retaining screws to 10 N.m (89 lb in).





6. Connect the I/P harness vacuum source line (1) to the HVAC module vacuum harness (2).





7. Install the blower motor W/impeller.
8. Connect the wiring harness electrical connector to the blower motor resistor.





9. Position and align the RH floor air outlet duct - rear to the HVAC module, then push firmly and evenly to secure the duct.





10. Secure the carpet air outlet duct to the RH floor air outlet duct - rear.
Use a rotating motion to secure the carpet air outlet duct to the floor air outlet duct - rear.
11. Position the front floor carpet to the RH side of the driveline tunnel.





12. Install the RH floor air outlet duct to the HVAC module.
13. Install the floor air outlet duct retaining screws.

Tighten
Tighten the floor air outlet duct retaining screws to 1.6 N.m (14 lb in).





14. Install the passenger Supplemental Inflatable Restraint (SIR) bracket and the passenger knee bolster bracket.
15. Install the RH side window defogger outlet duct - lower.
15.1. Use a twisting motion to secure the defogger outlet duct - lower to the defogger outlet duct - upper, then to the windshield defroster duct.
15.2. Install the defogger outlet duct - lower retaining tabs to the passenger SIR bracket.





16. Position and align the LH floor air outlet duct - rear to the HVAC module, then push firmly and evenly to secure the duct.





17. Install the LH floor air outlet duct to the HVAC module.
18. Install the floor air outlet duct retaining screws.

Tighten
Tighten the floor air outlet duct retaining screws to 1.6 N.m (14 lb in).

19. Install the I/P center support bracket and the ignition switch housing bracket.





20. Connect the electrical connector to the temperature valve electric actuator.
21. Connect the Daytime running Lights (DRL) sensor electrical connector to the LH side of the windshield defroster duct, if equipped.





22. Install the LH side window defogger outlet duct - lower.
22.1. Use a twisting motion to secure the defogger outlet duct - lower to the defogger outlet duct - upper, then to the windshield defroster duct.
22.2. Install the push-in retainer.





23. Install the instrument panel cluster (IPC) into position.
24. Install the IPC to steering column bracket retaining screws.

Tighten
Tighten the IPC to steering column bracket retaining screws to 3.5 N.m (31 lb in).

25. Install the I/P upper trim pad.
26. Install the LH lower insulator panel.
27. Install the driver knee bolster trim panel.





28. Install the RH lower insulator panel. .
29. Install the I/P passenger compartment.
30. Install the I/P accessory trim plate.
32. Install the evaporator and HVAC module drain tube to the module; orientate the drain tube to contact the dash panel as shown (1).
33. Check to be sure that the drain tube is fully seated to the HVAC module.





34. Remove the cap or tape from the accumulator hose, evaporator tube - rear and the evaporator.
35. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the accumulator hose, evaporator tube - rear and the evaporator.
36. Lightly coat the new O-ring seals (1) with mineral base 525 viscosity refrigerant oil.

Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the O-ring seals to enter the refrigerant system.

37. Carefully slide the new O-ring seals (1) onto the accumulator hose and the evaporator tube - rear until seated.





38. Install the accumulator hose and evaporator tube - rear to the evaporator.
39. Install the accumulator hose to evaporator retaining bolt.

Tighten
Tighten the accumulator hose to evaporator retaining bolt to 16 N.m (12 lb ft).





40. Remove the cap or plug from the heater pipe assembly and the heater core.
41. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the heater pipe assembly and the heater core.
42. Lightly coat the new seal washers with coolant.
43. Carefully slide the new seal washers onto the heater pipe assembly until seated.
44. Install the heater pipe assembly to the heater core.
45. Install the heater pipe assembly retaining bolt.

Tighten
Tighten the heater pipe assembly retaining bolt to 16 N.m (12 lb ft).





46. Install the heater pipe bracket into position.
47. Install the heater pipe bracket retaining nut.

Tighten
Tighten the heater pipe bracket retaining nut to 10 N.m (89 lb in).

48. Install the engine intake manifold.
49. Install the battery heat shield.
50. Install the battery.
51. Connect the negative battery cable.

Tighten
Tighten the negative battery cable bolt to 15 N.m (11 lb ft).

52. Enable the SIR system.
53. Program the transmitters.
54. Refill the cooling system.
55. Inspect the heater core joint for leaks.
56. Evacuate and charge the refrigerant system.
57. Check the evaporator joint for leaks.