For 1990-2009 cars

### Removal Procedure

#### Tools Required

• | J 38042 Dual O-Ring Tube Seperator

• | J 37097-A Hose Clamp Remover/Installer

• | J 39500-B Refrigerant, Recovery and Recycling (ACR4) System

• | J 39400 Electronic Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the cross car support brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
3. Remove the IP assembly. Refer to Instrument Panel Assembly Removal in Instrument Panel, Gauges and Console.
4. Drain the cooling system. Refer to Cooling System Draining and Filling .
5. Disconnect the right bank spark plug wires and bracket. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
6. Remove the evaporator. Refer to Air Conditioning Evaporator Core Replacement .
7. Remove the heater hoses from the heater core using the J 37097-A .
8. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power Steering Systems.
9. Remove the air distributor. Refer to Air Distributor Duct Replacement .
10. Remove the aspirator adapter (C68 and CJ2).
11. Remove the heater and A/C programmer (C68 and CJ2). Refer to Programmer Replacement .
12. Remove the bolts (5) that attach the heater and A/C module assembly (3) to the front of the dash (4).
13. Remove the bolts (1) and the studs (2) that attach the heater and A/C assembly (3) to the front of the dash (4).
14. Reposition the insulation as needed.
15. Remove the remainder of the heater and A/C module assembly (3).

Rotate the assembly (3) as needed to clear the right rear corner of the engine.

16. If replacing the heater and A/C module assembly (3), transfer the heater core to a new module assembly (3).

### Installation Procedure

1. Install the heater and A/C module assembly (3) (partial).

Rotate the assembly (3) as needed to clear the right rear corner of the engine.

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.

2. Install the bolts (1) and the studs (2) to attach the heater and A/C module assembly (3) to the rear of the dash (4).

Reposition the insulation as needed.

Tighten
Tighten the bolts and the studs to 5 N·m (44 lb in).

3. Install the bolts (5) to attach the heater and A/C module assembly (3) to the front of the dash (4).

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

4. Install the heater and A/C programmer (C68 and CJ2). Refer to Programmer Replacement .
5. Install the aspirator adapter (C68 and CJ2).
6. Install the air distributor. Refer to Air Distributor Duct Replacement .
7. Install the vacuum source input to the right side of the air distributor.
8. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering Systems.
9. Install the heater hoses to the heater core using the J 37097-A .
10. Install the evaporator. Refer to Air Conditioning Evaporator Core Replacement .
11. Connect the right bank spark plug wires and bracket. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
12. Install the IP assembly. Refer to Instrument Panel Assembly Removal in Instrument Panel, Gauges and Console.
13. Install the cross car brace support. Refer to Cross Vehicle Brace Replacement in Body Front End.
14. Fill the cooling system. Refer to Cooling System Draining and Filling .
15. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging
16. Leak test the system. Refer to Leak Testing .