HVAC Module Assembly Replacement RHDD

Removal Procedure

1. Disable the SIR system. (Refer to "Disabling the SIR System" in this service manual.)
2. Record the pre-set radio stations.
3. Disconnect the negative battery cable.
4. Recover the refrigerant using an approved refrigerant recovery system.
5. Remove the air cleaner housing cover and air induction hose at the intake manifold.




6. Remove the suction hose and liquid line from the thermal expansion valve.

Notice

Place protective covers over A/C hoses, lines, TXV, and HVAC module to prevent contamination of A/C system.

7. Remove coolant reservoir cap.
8. Drain cooling system.
9. Remove the heater inlet hose from the engine outlet and blow remainder the coolant out of the heater core with an air hose in order to prevent coolant from spilling on the vehicle interior when removing HVAC module.
10. Install the heater inlet hose on the engine outlet and position clamp at 4 o'clock position as viewed from the left side of the vehicle.





Caution

Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

11. Raise the vehicle.
12. Move the clamps up the heater core inlet and outlet hoses.




13. Remove the hoses from the heater core




14. Remove for nuts holding lower HVAC module and blower unit to cowl.
• Left upper side of TXV
• Lower right side of TXV
• Left of module drain
• Lower left side of brake booster
15. Lower the vehicle.




16. Remove nut holding blower unit to cowl at right center of brake booster.




17. Remove the screws and carefully pull right and left end cap assemblies outward at clip locations.




18. Remove the screws and remove the arm rest, if equipped.




19. Lift the parking brake lever.
20. Remove the screw.
21. Remove the parking brake cover by lifting straight off lever.




22. Move the shifter to neutral. Remove the ashtray from the cup holder by lifting straight out.
23. Remove the cup holder from the console by pulling upwards starting at the rear edge.




24. Remove the ashtray bulb socket by lifting tab while sliding socket forward. Then pull socket straight out.
25. Remove the wiring harness from the cup holder.




26. Remove the window/mirror switch, if equipped, by sliding switch forward then lifting at the rear edge. Disconnect the electrical connectors.




27. If the vehicle does not have an arm rest, remove the rear screw cover by lifting at cut out.
28. Remove the rear console screws.




29. Remove left and right lower trim panel extensions by pulling outward at dual lock locations. Then rotate the panels outward to disengage hinges from console.




30. Remove the front console screws.
31. Move console rearward.
32. Disconnect the cigarette lighter electrical connector.
33. Remove the bulb socket from cigarette lighter by rotating clockwise and pulling straight out.




34. Lift the console at rear. Slide the console rearward and lift straight up to remove.




35. Depress the center pins inward to release radio/HVAC controller cover push pins fasteners.

Important

Do not push the center pins through fasteners.

36. Remove the fasteners and pull radio/HVAC controller cover rearward.
37. Disconnect traction control/fog lamp/rear defog electrical connector if equipped.




38. Remove the radio screws.
39. Push the spring clips in through D-holes on both sides of radio brace.
40. Pull the radio out slightly to access the rear of the radio.




41. Disconnect the electrical connector and antenna.
42. Remove the radio.




43. Disconnect blower switch, A/C-Recirc and lighting electrical connectors.




44. Remove the temperature and mode cables from HVAC control by squeezing lock tabs together while pulling cable housing straight up.
45. Remove the cables from pins by pulling straight up. (Service cables shown in illustration.




46. Remove the screws and HVAC controller.




47. Remove the closeout seal by releasing from tabs.




48. Remove the screw and ground wire from H-bracket.
49. Remove the wiring harness from H-bracket.




50. Remove the screw and disconnect the rear electrical connector from the instrument panel block screw.




51. Remove the instrument panel junction block screw.
52. Insert a small flat blade screwdriver from passenger side, to release lock tabs on the instrument panel junction block and slide off of mounting pads.
53. Feed the instrument panel junction block through H-brackets towards the front of the car.




54. Remove the bolts from H-Bracket.




55. Remove the screws from the data link connector(DLC) and steering column filer panel.




56. Lower steering column filler panel and remove hood release handle assembly.
57. Route hood release handle assembly forward through the I/P carrier to the cowl.




58. Disconnect the ignition switch electrical connector at the right steering column bolt.
59. Remove the steering column bolts and the lower column on the front seat.




60. Remove the fasteners and pull the instrument cluster trim bezel rearward at clip locations.
61. Disconnect the electrical connector from the instrument panel dimmer switch.




62. Remove the connector position assurance (CPA) devices and disconnect the electrical connectors from the instrument cluster by squeezing the tabs on each side of connector.




63. Remove the front and rear instrument cluster screws.
64. Remove the instrument cluster.




65. Remove the dimmer and defroster switch wiring harness from the instrument panel reinforcement using a screwdriver to remove rosebud retainer. Replace retainer if damaged during removal.
66. Feed connectors through reinforcement towards front of car.




67. Remove the passenger side air bag harness from cross car beam and energy absorber.




68. Remove the glove box door stops by rotating 90 degrees and let door hang down.
69. Remove the screws from the glove box and compartment and striker.
70. Remove the glove box assembly by pulling rearward at the clip locations.




71. Disconnect PCM electrical connectors.




72. Loosen PCM retaining nut and lift PCM upward and remove.




73. Use the illustration to determine fastener location and direction of removal.




74. Remove the nut, screws and instrument panel pad/reinforcement assembly.




75. Detach wiring harness rosebud fastener from rear of HVAC module.




76. Remove wiring harness rosebud fasteners from side of HVAC module.
77. Remove wiring harness rosebud fastener from left module mounting bracket.




78. Remove lower heater duct screws.





Notice

Be careful not to damage foam seal.

79. For Coupes, slide heater duct downward and then left, into passenger side footwell.
80. For Sedans and Wagons, use a flat blade screwdriver to bend the right side heater duct flange outward at cut lines, then slide duct left into passenger side footwell with wiring harness.
81. Remove BTSI cable from heater duct.




82. Remove the screws and center air outlet duct.




83. Remove the screws and unsnap windshield defroster nozzle from the mode valve assembly




84. Remove the defroster nozzle by rotating front of nozzle up and away from the windshield.




85. Disconnect the blower motor resistor connector.




86. Disconnect the blower motor electrical connectors.




87. Remove ABS module from HVAC module by gently pulling outward to disengage hook and loop fastener, and then rearward to disengage alignment pins.
88. Disconnect ABS module electrical connector and remove module.
89. Remove shift lock cable from clamp at front edge of heater pipe cover.




90. Remove HVAC module mounting brackets to beam bolts.




91. Remove blower unit bracket to cowl screw.




92. Disconnect air valve actuator electrical connector.




93. Remove blower unit from vehicle.




94. Remove the HVAC module from the vehicle.




95. Remove TXV from HVAC module.
96. Place protective cover over evaporator pipes to prevent contamination of A/C system.

Installation Procedure

Notice

Use only R-12 refrigerant oil to lubricate the O-rings. Use of R-134a (PAG) oil will cause premature corrosion of fitting joints. Do not lubricate seal washers.

1. Install TXV to HVAC module.




2. Install the new cowl panel seals on the heater core pipes, case drain, and evaporator block.




3. Install the HVAC module through the cowl.




4. Install HVAC module mounting bracket to beam bolts, but do not tighten.




5. Connect air valve actuator electrical connector.




6. Install blower unit into HVAC module and through cowl.




7. Install blower unit bracket to cowl bolt.
Tighten

Tighten to 2.2 N·m (20 lbs in)





8. Install blower unit to cowl nut at right side of brake booster.
Tighten

Tighten to 5 N·m (44 lbs in)

Caution

Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

9. Raise vehicle.
10. Install HVAC module and blower unit nuts.
Tighten

Tighten to 5 N·m (44 lbs in)






Important

Be careful not to push hoses onto heater core pipes so far that foam seal is contacted.

11. Install hose and clamp on heater core outlet. Install clamp at 7-8 o'clock position.
12. Install hose and clamp on heater core inlet. Install clamp at 6 o'clock position.
13. Lower vehicle.




14. Tighten HVAC module mounting brackets to beam bolts.
Tighten

Tighten to 6 N·m (53 lbs in)





15. Connect the blower motor electrical connector.




16. Connect ABS module electrical connector.
17. Install ABS module alignment pins into HVAC module flange and rotate ABS module toward HVAC module to engage hook and loop retainer.
18. Install park lock cable into clamp at forward edge of heater pipe cover.




19. Connect the blower motor resistor electrical connector.




20. Install windshield defroster nozzle onto HVAC module and install screws. Make sure the duct is snapped on both sides of HVAC module.
Tighten

Tighten to 2.2 N·m (20 lbs in)





21. Install the center air outlet duct and screws.
Tighten

Tighten to 10 N·m (89 lbs in).





22. Install brake transaxle interrupt cable into heater duct clamp.

Notice

Be careful not to damage foam seal.

23. Install heater duct to HVAC module.
For Coupes, slide duct under HVAC module from left side and raisee into installed position. Install heater duct screws.



24. Install heater duct to HVAC module.
For Sedans/Wagons cut right heater duct flange off as shown, and slide duct into position between HVAC module and rear seat heater duct. Install left heater duct screw.



25. Install wiring harness rosebud fastener at rear of HVAC module.




26. Install wiring harness fastener into side of HVAC module.
27. Install wiring harness fastener into left HVAC module bracket.




28. Place instrument panel junction block in position.

Important

Make sure PSIR connector harness is on top of beam.

29. Install the instrument panel pad/reinforcement assembly.
30. Install and tighten the nut and bolts.
Tighten

Tighten to 10 N·m(89 lbs in).





31. Install PCM into mounting bracket and tighten nut.
Tighten

Tighten to 10 N·m(89 lbs in).





32. Connect PCM electrical connectors.




33. Install the passenger side air bag harness to energy absorber and cross-car beam




34. Install the dimmer switch and defroster switch wiring harness to instrument panel reinforcement.




35. Install the instument cluster.
36. Install and tighten the screws.
Tighten

Tighten to 3 N·m (26 lbs in).





37. Connect the electrical connectors to the instrument cluster.
38. Install the CPA.




39. Connect the electrical connector to the dimmer switch.
40. Install the instrument cluster trim bezel. Push in at the clip locations.
41. Install the push pin fasteners.




42. Raise the steering column into position.
43. Install and tighten the bolts.
Tighten

Tighten the 35 N·m (26 lbs ft).





44. Route the hood release handle assembly through I/P and then install steering column filler panel.
Tighten

Tighten to 1.5 N·m (13 lbs in).





45. Install the steering column filler panel and DLC.
46. Install and tighten the screws.
Tighten

Tighten to 2.2 N·m (20 lbs in).





47. Install and tighten bolts into H-bracket.
Tighten

Tighten bolts to 25 N·m (19 lbs in).





48. Feed the instrument panel juction block through the H-bracket towards the rear of the car.
49. Slide the IPJB on mounting pads to lock the tabs.
50. Install and tighten IPJB screw.




51. Connect the rear electrical connector to IPJB
52. Tighten the screw.
Tighten

Tighten to 6.5 N·m (5 lbs ft).





53. Install the wiring harness, ground wire and screw to H-bracket.
54. Tighten the screw
Tighten

Tighten to 2.2 N·m (20 lbs in).





55. Install the closeout seal.

Important

Make sure the tabs engage closeout seal holes on both sides





56. Install HVAC control.
57. Install and tighten screws.
Tighten

Tighten to 2.5 N·m (2.2 lbs in).





Install the temperature and mode cables over the pins
Cable Identification:
• Temperature cable- white
• Mode cable-black
59. Install cable housings into channel and push down to lock.




60. Place HVAC control mode lever completely to the right-defroster position.




61. Verify that mode cam is still in full counterclockwise position.
62. Press mode cable housing firmly into retainer clip to lock.
63. Move HVAC control mode lever through modes to verify proper installation.




64. Place HVAC control temperature lever completely to the right - full hot.




65. Verify that temperature cam is still in full counterclocwise position.
66. Press temperature cable housing firmly into retainer clip to lock.
67. Move HVAC control temperature lever from hot to cold to verify proper installation.




68. Connect the blower switch, A/C-Recirc and lighting electrical connectors.

Important

Make sure wiring harnesses do not interfere with control lever movement.





69. Connect the electrical connector and antenna to radio.




70. Install the radio.

Important

Make sure spring clips are seated in D-holes on both sides.

71. Install and tighten the screws.
Tighten

Tighten to 2.5 N·m (22 lbs in).

72. Connect the traction control/fog lamp/rear defog electrical connector, if equipped.
73. Install the radio/HVAC control cover. Push in at clip locations.
74. Install the push pins and lock.




75. Install glove box and snap in at clip locations.
76. Install and torqe screws.
Tighten

Tighten to 2.2 N·m (20 lbs in).

77. Install glove box door stops.
78. Adjust striker as necessary.




79. Place the shifter in neutral.
80. Lower the front of the console over shifter.
81. Lower the rear of the console over parking brake lever onto rear mounting pad.

Important

Make sure to place window/mirror and ashtray light connectors through openings into position.





82. Move the console rearward.
83. Install the cigarette lighter bulb through opening and rotate counterclockwise.
84. Connect cigarette lighter electrical connector.
85. Move the console forward into position.

Important

Make sure that the upper tabs on front of the console engage sheet metal on lower I/P brace.

86. Install and tighten the front console screws.
Tighten

Tighten to 1.2 N·m (11 lbs in).





87. Install the left and right lower trim panel extensions by inserting hinges into console openings. Then rotate closed and push in at dual lock location.




88. For vehicles without the console armrest:
• Align the rear of console with pin on mounting pad.
• Install and tighten screws.
• Tighten

  Tighten to 1.6 N·m (14 lb in).

  Install the screw cover.




89. Connect the window/mirror switch electrical connectors.
90. Install the window/mirror switch by inserting front edge into opening. Then push the rear edge down into position.




91. Insert the bulb through the opening until bulb socket is flush with cup holder. Push socket down to engage lock tab.
92. Install the wiring harness to the cup holder.




93. Install the cupholder by inserting through console opening and pushing straight down,




94. Install the parking brake cover over lever.
95. Install and tighten the screw.

Notice

Do not overtighten screw or it may pull through cover.

Tighten

Tighten to 1.6 N·m (14 lbs in).





96. Install the arm rest unit into the console, if equipped. Install and tighten the screws.
Tighten

Tighten to 1.6 N·m (14 lbs in).





97. Install the right and left end cap assemblies.
98. Install and tighten the screws.
Tighten

Tighten to 2.2 N·m (20 lbs in).





99. Lubricate O-rings with R-12 Refrigerant oil (mineral) and install new O-rings on suction hose and liquid line.
100. Insall the liquid line on the TXV.
Tighten

Tighten to 25 N·m (19 lbs ft).

101. Install the suction hose on the TXV.
Tighten

Tighten to 25 N·m (19 lbs ft).





102. Install the air cleaner housing cover and air induction hose.
103. Fill and pressure test the cooling system.
104. Evacuate, charge, and leak test A/C system. Perform A/C Performance Test.
105. Connect the negative battery cable.
Tighten

Tighten to 17 N·m (151 lbs in).

106. Set the clock to proper time if equipped.
107. Enable the SIR system. (Refer to "Enabling the SIR System" in this service manual.)
108. Reset the radio stations.