HVAC Module Assembly Replacement Non-HP2

Special Tools

J 43181 Heater Line QC Release Tool

1. Drain the engine coolant. Refer to Cooling System Draining and Filling .



2. Using the J 43181 disconnect the inlet heater hose from the heater core.

2.1.	Install the J 43181 to the heater core pipe.

2.2.	Close the tool around the heater core pipe.

2.3.	Firmly pull the tool into the quick connect end of the heater hose.

2.4.	Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core.

3. Using the J 43181 disconnect the surge tank outlet hose from the heater core.

3.1.	Install the J 43181 to the heater core pipe.

3.2.	Close the tool around the heater core pipe.

3.3.	Firmly pull the tool into the quick connect end of the heater hose.

3.4.	Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core.

4. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
5. Remove the battery. Refer to Battery Replacement .
6. Remove the accumulator. Refer to Air Conditioning Accumulator Replacement .
7. Remove the instrument panel to the service position. Refer to Instrument Panel Service Positioning .
8. Remove the HVAC module drain hose.
9. Disconnect the electrical harnesses and the ground connections from the HVAC module.



10. Locate the rear engine cover (1) on rear of intake manifold.

Important: Ensure that any wiring harness does not interfere with the drilling process of the rear engine cover.




11. Reposition the acoustic foam (if applicable) down from the access location (1).

Important: Drill an 25.4 mm (1 in.) diameter hole in the rear engine cover (1) to access the HVAC module retaining nut located behind rear engine cover.




12. Remove the nuts (2) from the HVAC module (3).
13. Remove the bolts (1) from the HVAC module (3).
14. Remove the HVAC module (3).

1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary.
2. Install the HVAC module (3).

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 nuts (2) to the HVAC module (3).

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

4. Install the bolts (1) to the HVAC module (3).

Tighten
Tighten the bolts to 4 N·m (35 lb in).

5. Reposition acoustic foam (if applicable) to original position or cover access hole with equivalent foam tape (1).
6. Connect the electrical harness and the ground connections.
7. Install the HVAC module drain hose.
8. Install the instrument panel . Refer to Instrument Panel Service Positioning .
9. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
10. Install the battery. Refer to Battery Replacement .
11. Install the accumulator. Refer to Air Conditioning Accumulator Replacement .



12. Install the surge tank outlet hose to the heater core.

Firmly push the quick connect onto the heater core pipe until you hear an audible click.

13. Install the inlet heater hose to the heater core.

Firmly push the quick connect onto the heater core pipe until you hear an audible click.

14. Fill the engine coolant. Refer to Cooling System Draining and Filling .