For 1990-2009 cars

#### Tools Required

• | J 39400-A Halogen Leak Detector

• | J 43600 ACR 2000 Air Conditioning Service Center

### Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the heater inlet hose:

• | From the auxiliary water pump outlet on L81 engines.

• | From the thermostat outlet on L61 engines.

5. Remove the heater outlet hose:

• | From the cylinder head bridge on L81 engines.

• | From the block inlet on L61 engines.

6. Place the end of the heater return hose in a container and apply low pressure 34 kPa (5 psi) of shop air to the heater inlet hose to blow the coolant out of the heater core.
7. Install the heater return hose to the nipple and position the clamp at 6 o'clock position on L81, 12 o'clock position on L61.
8. Install the heater inlet hose to the auxiliary water pump outlet on L81, or at the thermostat outlet on L61 and position the clamps at 12 o'clock .

Important: Green plastic rings may be found hanging on the pipes after hose removal, these are manufacturing aids and should be discarded.

9. Remove the heater inlet hose from the heater core pipe.

9.1. | Depress the quick connect collar tab located at 6 o'clock

9.2. | Pull the black collar toward the front of vehicle

9.3. | Pull the quick connect off the heater core pipe

10. Remove the heater outlet hose from the heater core pipe.

10.1. | Depress the quick connect collar tab located at 6 o'clock

10.2. | Pull the black collar toward the front of vehicle

10.3. | Pull the quick connect off the heater core pipe

11. Remove the evaporator hose assembly to TXV nut.
12. Remove the evaporator hose assembly from the TXV.
13. Remove the I/P assembly. Refer to Instrument Panel Assembly Replacement in Instrument Panel, Gages and Console.
14. Disconnect the I/P harness electrical connector from the module harness.
15. Remove the wiper arm assemblies. Refer to Windshield Wiper Arm Replacement in Washer/Wiper Systems.
16. Remove the cowl retaining nuts and remove the cowl screen assembly.
17. Rotate the locking tabs outward to release the filter assembly.
18. Remove the filter by lifting straight up.
19. Remove the wiper module retaining bolts and slide the wiper module to the right.
20. Remove the filter housing attachment bolts and remove the filter housing.
21. Remove the evaporator drain tube screw.
22. Remove the evaporator drain tube.
23. Remove the HVAC module to front of dash bolts.
24. Remove the HVAC module from the vehicle.

### Installation Procedure

1. Install the module into the vehicle.
2. Install the HVAC module to the front of the dash and hand start the bolts.
3. Remove the filter housing seal using a small flat bladed tool.
4. Install a new filter housing seal.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the filter housing and screws.

Tighten
Tighten the screws to 3.5 N·m (31 lb in).

6. Reposition the wiper module and install the bolts.

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

7. Tighten the HVAC module to front of the dash bolts.

Tighten
Tighten the bolts to 4.5 N·m (40 lb in).

8. Install the evaporator drain tube.
9. Install the evaporator drain tube bolt.

Tighten
Tighten the bolt to 3.5 N·m (31 lb in).

10. Install the passenger compartment air filter paying special attention to the air flow direction indicator.
11. Rotate the locking tabs to secure the air filter in place.
12. Install the cowl screen and the fasteners.

Tighten
Tighten the fasteners to 1.0 N·m (9 lb in).

13. Close the filter access door.
14. Install the wiper arm assemblies. Refer to Windshield Wiper Arm Replacement in Washer/Wiper Systems.
15. Install the heater inlet hose.

• | Hold the hose by black quick connect collar and slide the hose onto the heater core pipe until the quick connect collar engages over the bead on the heater core pipe

• | Ensure that a green band is visible in the quick connect collar

• | Pull on the hose to ensure it is properly seated

16. Install the heater outlet hose.

• | Install the heater outlet hose, closest to passenger side

• | Ensure that a green band is visible in the quick connect collar

• | Pull on the hose to ensure the hose is properly seated

17. Install the I/P assembly. Refer to Instrument Panel Assembly Replacement in Instrument Panel, Gages and Console.
18. Remove the protective cap from the TXV.
19. Thoroughly clean the O-ring surfaces of the TXV.
20. Remove the caps.
21. Install new O-rings. Refer to O-Ring Replacement .
22. Install the evaporator hose assembly block to the TXV.
23. Install the evaporator hose assembly block to TXV nut.

Tighten
Tighten the nut to 7 N·m (62 lb in).

24. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
25. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
26. Using the J 39400-A leak test the fittings of the component.