HVAC Module: Installation

NOTE: Before installing the HVAC module to the vehicle, ensure that the HVAC module mounting studs are located in the proper positions.

If replacing the HVAC module, transfer the components from the old HVAC module as necessary. Install the HVAC module to the vehicle. Connect the heater hoses to the heater core.
Connect all of the vacuum lines to the heater assembly. Connect all of the electrical connectors to the HVAC module. Install the bottom right HVAC module mounting bolt from inside the vehicle approximately halfway into the threads.
On the Utility only, install the HVAC module mounting stud located at the lower right side of the heater core to heater hoses connection in the engine compartment. Tighten the HVAC module mounting stud to specification. See TORQUE SPECIFICATIONS .
On vehicles with A/C only, raise the vehicle. On the Utility only, install the bottom right HVAC mounting studs. Ask an assistant to pull the bottom right corner of the HVAC module back from inside the vehicle. Tighten the HVAC module mounting stud to specification.
On the Utility only, install the A/C evaporator and blower module heat shield bracket. Install the HVAC module mounting nuts. Tighten the HVAC module mounting nuts to specification. See TORQUE SPECIFICATIONS . On the Utility only, slide the A/C evaporator and blower module heat shield into the original position.
On the Utility only, install the A/C evaporator and blower module heat shield screws. Tighten the A/C evaporator and blower module heat shield screws specification. See TORQUE SPECIFICATIONS .
On vehicles with A/C only, install the right front tire and lower the vehicle. Install the bottom right HVAC module mounting bolt from inside the vehicle. Tighten the HVAC module mounting bolt to specification.
On vehicles with A/C only, install the right wheel house panel. Install the HVAC module mounting nut located at the lower right side of the heater core to heater connection. Tighten the HVAC module mounting nut to specification. See TORQUE SPECIFICATIONS .
Install the HVAC module mounting bolt located at the lower left side of the heater core to heater hose connection. Tighten the HVAC module mounting bolt to specification. On vehicles with the 2.2L engine only, install the engine wiring harness bracket located at the rear of the intake manifold.

NOTE: Use the same mounting bolt marked during removal for the HVAC module during the installation process. Other mounting bolts are longer and will obstruct the operation of the temperature door.

Install the HVAC module mounting bolt through the blower motor resistor or service access cover opening. Tighten the HVAC module mounting bolt to specification. On vehicles without automatic climate control, install the blower motor resistor. On vehicles with automatic climate control only, install the service access cover.
On vehicles with automatic climate control only, install the service access cover mounting screws. On vehicles with automatic climate control only, install the outer layer of the A/C evaporator and blower module.

NOTE: Do not use RTV. Apply the adhesive bead as straight as possible. Allow the adhesive to set for 15 minutes or until the adhesive becomes tacky.

Seal the cut line using Black weatherstrip adhesive. Refill the engine coolant. Install the instrument panel. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
Calibrate the HVAC module actuator (if necessary). See HVAC MODULE ACTUATOR CALIBRATION under ADJUSTMENTS.