Tools Required

Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disconnect the negative battery cable. Refer to Battery Replacement in Engine Electrical.



2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Use J 38185 to reposition the inlet heater hose from the heater core.
5. Remove the inlet heater hose from the heater core.
6. Use J 38185 to reposition the outlet heater hose from the heater core.
7. Remove the outlet heater hose from the heater core.
8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
9. Remove the evaporator hose from the evaporator.
10. Remove the drain tube elbow from the evaporator block heater case plate.



11. Remove the nuts holding the heater case plate for the heater pipes.
12. Remove the heater case plate and the seals for the heater pipes.
13. Remove the nuts holding the heater case plate for the evaporator block.
14. Remove the heater case plate and seal for the evaporator block.
15. Remove the nut for the HVAC module assembly bracket.
16. Lower the vehicle.
17. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls - 2.2 L.
18. Release the under hood electrical center and position aside.



19. Loosen the steering column brace bolts (1) behind the under hood electrical center.
20. Remove the instrument panel carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages, and Console.



21. Remove the bolt from the bracket joining the cross vehicle beam to the HVAC module.



22. Release the body control module from the cross vehicle beam.
23. Remove HVAC duct work from the cross vehicle beam.



24. Remove the 2 remaining bolts for the steering column brace.



25. Remove the nuts and bolts joining the cross vehicle beam (1) to the front of the dash (2).



26. Remove the cross vehicle beam from the vehicle.
27. Remove the floor air duct from the HVAC module.
28. Remove the air distribution duct.



29. Remove the daytime running lights sensor wiring harness clip (1) from the HVAC module assembly.
30. Disconnect the I/P lamp dimmer switch electrical connector (2).
31. Remove the wiring harness clips (3) from the HVAC module assembly bracket.
32. Disconnect the vacuum source hose (4) from the vacuum tank.



33. Disconnect the blower motor resistor electrical connector.
34. Disconnect the blower motor electrical connector.



35. Disconnect the temperature actuator electrical connector.



36. Remove the HVAC module assembly.

1. Position the HVAC module assembly to the vehicle.



2. Connect the temperature actuator electrical connector.



3. Connect the blower motor resistor electrical connector.
4. Connect the blower motor electrical connector.



5. Install the wiring harness clips (3) to the HVAC module assembly bracket.
6. Install the daytime running lights sensor wiring harness clip (1) from the HVAC module assembly.
7. Connect the I/P lamp dimmer switch electrical connector (2).
8. Connect the vacuum supply hose (4) to the vacuum tank.
9. Install the air distribution duct.
10. Install the floor air duct to the HVAC module.



11. Install the cross vehicle beam (1) to the front of the dash (2).

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.

12. Install the nuts and bolts for the cross vehicle beam.

Tighten
Tighten the nut and bolts to 20 N·m (15 lb ft).




13. Install the steering column mounting brace bolts.

Tighten
Tighten the bolts to 26 N·m (19 lb ft).

14. Install HVAC duct work to the cross vehicle beam.



15. Install the body control module to the cross vehicle beam.



16. Connect the wiring harness to the cross vehicle beam.



17. Install the bolt retaining the cross vehicle beam to the HVAC module.

Tighten
Tighten the bolt retaining the cross vehicle beam to the HVAC module to 10 N·m (89 lb in).

18. Install the instrument panel carrier to the cross vehicle beam. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages, and Console.



19. Tighten the steering column brace bolts (1) behind the under hood electrical center for the steering column brace.

Tighten
Tighten the bolts to 26 N·m (19 lb ft).

20. Install the under hood electrical center.
21. Install the air cleaner assembly to the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls - 2.2 L.
22. Raise the vehicle.
23. Install the nut for the HVAC module assembly bracket.

Tighten
Tighten the nut to 10 N·m (89 lb in).




24. Install the heater case plate and the seals for the heater pipes.
25. Install the nuts holding the heater case plate for the heater pipes.
26. Install the heater case plate and seal for the evaporator block.
27. Install the nuts holding the heater case plate for the evaporator block.

Tighten
Tighten the nuts to 10 N·m (89 lb in).




28. Install the drain tube elbow to the evaporator block heater case plate.
29. Install the evaporator hose to the evaporator.
30. Install the outlet heater hoses to the heater core.
31. Install the inlet heater hose to the heater core.
32. Lower the vehicle.
33. Connect the negative battery cable. Refer to Battery Replacement in Engine Electrical.
34. Fill the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
35. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
36. Leak test the fittings of the component using the J 39400-A .