For 1990-2009 cars

## HVAC Module Assembly Replacement RHD

#### Tools Required

• | J 38185 Hose Clamp Pliers

• | J 39400 Halogen Leak Detector

### Removal Procedure

Caution: Refer to Safety Glasses Caution in the Preface section.

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the engine cover. Refer to Engine Cover Replacement in Engine Mechanical - 3.6L or Engine Cover Replacement Engine Mechanical - 6.0L
4. Drain the cooling system. Refer to Cooling System Draining and Filling.

Important: Mark position of heater hoses (3) and heater hose retaining clamps (1) before removal to make sure of correct alignment during assembly.

5. Using J 38185 compress the heater hose retaining clamps (1) and slide 50 mm (2 in) along the heater hose (3).
6. Remove the heater hoses (3) from the heater core pipes (2).
7. Remove the exhaust manifold heat shield to air box retaining clips (2).
8. Remove the exhaust manifold heat shield (1).
9. Remove the insulation panel to air box retaining clips (2).
10. Remove the insulation panel (1) from the engine compartment.
11. Remove the remote battery positive post cover (1).
12. Remove the remote battery positive post to wiring harness retaining bolt (1).
13. Remove the starter motor power cable (2) and position aside.
14. Remove the suction pipe upper to suction pipe lower retaining nut (1).
15. Remove the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
16. Detach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).
17. Disconnect the suction pipe upper (1) from the suction pipe lower (2).

Important: The sealing washer (3) is a single use item and must be discarded after use.

18. Remove the sealing washer (3). Refer to Sealing Washer Replacement .

Discard the sealing washer

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

19. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).
20. Remove the suction pipe/liquid pipe pad to thermal expansion (TX) valve retaining nut (1).
21. Disconnect the suction pipe/liquid pipe pad (3) from the TX valve (1).

Important: The sealing washers (2) are a single use item and must be discarded after use.

22. Remove the sealing washers (2). Refer to Sealing Washer Replacement.

Discard the sealing washers

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

23. Cap or plug the suction pipe (4), liquid pipe (5) and the TX valve (1).
24. Remove the HVAC module assembly to bulkhead retaining bolts (1).
25. Remove the I/P centre support bracket. Refer to Instrument Panel Retainer Replacement.
26. Remove the I/P upper trim pad. Refer to Instrument Panel Upper Trim Pad Replacement.
27. Remove the HVAC module assembly to vehicle body retaining screws (1).
28. Remove the I/P carrier. Refer to Instrument Panel Carrier Replacement.

Important: To remove the HVAC module assembly from the vehicle move the HVAC module assembly towards the back of the car off the drain assembly and downwards to clear locating pins from datum bracket.

29. Remove the HVAC module assembly (3) from the vehicle body (2).

### Installation Procedure

Important: Make sure the HVAC module assembly (3) fits into the drain assembly

1. Install the HVAC module assembly to the vehicle (2).
2. Install the instrument panel (I/P) carrier. Refer to Instrument Panel Carrier Replacement.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the HVAC module assembly to I/P carrier retaining screws (1).

Tighten
Tighten the screws to 9 N·m.80 lb in.

4. Install the I/P upper trim pad. Refer to Instrument Panel Upper Trim Pad Replacement.
5. Install the I/P retainer bracket. Refer to Instrument Panel Retainer Replacement .
6. Install the HVAC module assembly to bulkhead retaining bolts (1).

Tighten
Tighten the nuts to 7 N·m.62 lb in.

7. Remove the plugs or caps from the suction pipe (4), liquid pipe (5) and the thermal expansion (TX) valve (1).

Important: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

8. Install NEW sealing washers (2). Refer to Sealing Washer Replacement.
9. Connect the suction pipe/liquid pipe pad (3) to the TX Valve (1).

Notice: Refer to Fastener Notice in the Preface section.

10. Install the suction pipe/liquid pipe pad to TX valve retaining nut (1).

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

11. Remove the plugs or caps from the suction pipe upper (1) and the suction pipe lower (2).

Important: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

12. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement.
13. Install the suction pipe upper (1) to the suction pipe lower (2).
14. Attach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).
15. Install the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
16. Install the suction pipe upper to suction pipe lower retaining nut (1).

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

17. Install the starter motor positive cable (2) to the remote battery positive post.
18. Install the remote battery positive post to wiring harness retaining bolt (1).

Tighten
Tighten the bolt to 15 N·m (11 lb ft).

Important: Make sure the clips on the remote battery positive post cover (1) are engaged to avoid an induced rattle condition.

19. Install the remote battery positive post cover (1) to the remote battery positive post.
20. Install the insulation panel (1) to the left rear side engine compartment.
21. Install the insulation panel to air box retaining clips (2).
22. Install the exhaust manifold heat shield (1).
23. Install the exhaust manifold heat shield to air box retaining clips (2).
24. Connect the heater hoses (3) to the heater core pipes (2).
25. Using J 38185 , slide the heater hose retaining clamps (1) back into the original position on the heater hoses (3).
26. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
27. Fill the cooling system. Refer to Cooling System Draining and Filling .
28. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
29. Leak test the fittings of the component using J 39400 .
30. Install the engine cover. Refer to Engine Cover Replacement for 3.6L engine or Engine Cover Replacement for 6.0L engine.