For 1990-2009 cars

### Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Disconnect the battery negative cable.
3. Drain the cooling system. Refer to Cooling System Draining and Filling .
4. Remove the heater hose quick connects from the heater core pipes:

• | Raise the air inlet screen on the passenger side and open the access door near the pollen filter.

• | Squeeze the tabs on the locking collar and pull back on the sleeve in order to unlock.

• | Carefully pull back the tabs in order to remove the disconnects.

• | Discard the green assembly markers (1) if attached.

5. Remove the evaporator line extension bolt from the cowl.
6. Remove the steering column. Refer to Steering Column Replacement .
7. Remove the I/P carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges and Console.
8. Remove the vacuum line connection at the cowl.
9. Disconnect the electrically operated actuator connectors.
10. Remove the heater core pipe bracket screw.
11. Remove the heater core pipe bracket.
12. Remove the heater core inlet and outlet pipe retaining bracket screw.
13. Remove the heater core inlet and outlet pipes.
14. Remove the I/P support brace bolt from the I/P.
15. Remove the I/P support brace bolt from the transmission well.
16. Remove the I/P support brace.
17. Remove the following components from the vacuum actuators:

• | The vacuum hoses

• | The electrical connections

18. Remove the two air distribution module engine compartment screws.
19. Remove the module interior nut.
20. Remove the LH/RH floor rear supply duct screws from the module.
21. Remove the ducts from the module.
22. Reposition the wiring harness in order to allow the removal of the module.
23. Remove the module:

• | Carefully lift the upper vents from under the rubber seal.

• | Angle the module outward in order to remove.

### Installation Procedure

1. Install the air distribution module.
2. Position the wiring harness in order to facilitate the I/P carrier installation.
3. Install the RH/LH floor rear supply ducts.
4. Install the duct screws until fully seated and not stripped.

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.

5. Install the module interior nut.

Tighten
Tighten the module interior nut to 4 N·m (35 lb in).

6. Install the module engine compartment screws.

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

7. Install the following vacuum actuator components:

• | The electrical connections

• | The hoses

8. Position the I/P support brace at the I/P and at the transmission well.
9. Install the I/P support brace bolts at the I/P and at the transmission well.

Tighten
Tighten the bolts to 22 N·m (16 lb ft).

10. Install the heater core inlet and outlet pipes:

• | Use new O-rings.

• | Lightly lubricate the O-rings with coolant.

11. Install the heater core inlet and outlet pipe retaining bracket screw.

Tighten
Tighten the screw to 5 N·m (44 lb in).

12. Install the heater core pipe bracket.
13. Install the heater core pipe bracket screw until fully seated and not stripped.
14. Connect the electrically operated actuator connectors.
15. Connect the vacuum line connection at the cowl.
16. Install the I/P carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges and Console.
17. Install the steering column. Refer to Steering Column Replacement .
18. Install the evaporator line extension bolt to the cowl.

Tighten
Tighten the bolt to 20 N·m (15 lb ft).

19. Install the heater hose quick connects to the heater core pipe connections:

• | Discard green assembly marker (1) if not attached to the quick connect.

• | Inspect that the quick connects are fully seated.

• | Squeeze the locking tabs (2) and push the retaining sleeve (3) into the locked position.

• | Close the access door near the pollen filter and lower the air inlet screen on the passenger side.

20. Fill the cooling system. Refer to Cooling System Draining and Filling .
21. Connect the battery negative cable.
22. Reprogram applicable accessories.
23. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
24. Leak test the A/C system.