2026-08-09

HVAC Assembly - Front (Remove and Replace)

Correction Code 18101002

Warning
Only technicians who have been trained in High Voltage (HV) Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper Personal Protective Equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.
  • 2023-12-5: Revised procedure to the latest vehicle validation.

Removal

  1. Use the vehicle touchscreen to open the hood, the rear hatch, and all of the doors of the vehicle.
    Note
    Walk around and open the hood.
  2. Remove the underhood aprons.
    Note
    (x4) aprons; LH and RH aprons have (x1) clip each.
  3. Recover the refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  4. Move the driver and front passenger seats rearward.
    Note
    Easier to remove the center console later in this procedure.
  5. Open the glove box.
    Note
    Press the button on the RH side of MCU bezel.
  6. Remove the lower glove box trim.
  7. Remove the upper glove box trim.
  8. Remove the glove box from the vehicle.
    Note
    (x6) T20 screws, (x3) electrical connectors
  9. Remove both side IP side end caps.
    Note
    (x2) pc.
  10. Remove the carpeted floor mats from both front seating areas.
  11. Release the upper leather side trims of the LH and RH center console.
  12. Remove the RH and LH center console carpeted closeout panels.
  13. Remove both rear welcome plates.
  14. Remove the LH side B-Pillar rear trim.
    Note
    (x1) T25 patch screw
  15. Partially remove the LH side lower A-pillar weather seal.
  16. Remove the LH lower A-pillar trim.
  17. Remove the LH mid A-pillar trim from the vehicle.
    Note
    (x1) T25 patch screws
  18. Remove the driver knee bolster.
    Note
    (x2) screws, (x9) clips, T20, 2.3 Nm
  19. Remove the lower IP kick panel trim on the left side.
    Note
    (x1) electrical connector, (x2) teal mounting tabs
  20. Remove the RH rear B-pillar trim.
    Note
    (x1) T25 patch screw
  21. Partially remove the RH side lower A-pillar seal.
  22. Remove the RH side lower A-pillar trim.
  23. Remove the right side mid A-pillar trim from the vehicle.
    Note
    (x1) T25 patch screw
  24. Remove the RH side lower IP kick panel trim cover.
    Note
    (x1) electrical connection, (x2) teal mounting
  25. On the passenger side, fold back the carpeting and remove the foam false floor.
    Note
    (x2) fur tree push pins, (x2) push on flat round stud
  26. Move the second row seat into “easy” entry mode.
  27. Remove LH lower C-pillar trim (x1) T25 patch screw, and then remove the lower C-pillar from the vehicle.
    Note
    (x1) T25 screw
  28. Remove the LH trunk sill side trim.
    Note
    (x4) clips
  29. Release the (x2) screws that secure the LH mid C-Pillar trim, and then remove the trim from the vehicle.
    Note
    (x2) T20 screws
  30. Remove the rear load floor.
  31. Remove the trunk sill trim.
    Note
    (x4) clips, (x2) patch bolts, T25, 2.5 Nm. Discard after removal.
  32. Remove the underhood storage unit carpet liner.
    Note
    (x2) electrical connectors
  33. Remove the underhood storage unit.
    Note
    (x20) 10 mm bolts
  34. Remove the HEPA filter.
    Note
    Lift up from bottom and pull out.
  35. Remove the (x3) 17 mm nuts for the windshield wiper arms and disconnect the (x2) washer lines.
    Note
    (x3) 17 mm nuts (x2) washer hose connectors to cowl
  36. Remove both sides outer cowl covers.
    Note
    (x2) plastic anchor clips per side.
  37. Remove the center cowl section.
    Note
    (x5) push pins, (x1) harness edge clip (x1), washer hose one-way valve
  38. Remove the HEPA filter duct.
    Note
    (x1) clip
  39. Power down the vehicle.
  40. Disconnect 12V negative terminal and First Responder Loop.
    Note
    (x1) nut, 10mm, 5 Nm, (x1) connector. Wait at least 2 minutes before disconnecting modules or HV components.
  41. Remove the LH upper C-pillar trim.
    Note
    (x3) T20 screws, (x1) T25 patch screw
  42. Remove the trim from the LH side mid C-pillar trim.
  43. Remove the (x4) push pins from the rear trunk water fall carpeting.
  44. Remove the lower trunk trough trim.
  45. Remove the LH side C-pillar trunk side trim panel.
    Note
    (x1) 12v harness connector
  46. Remove the load floor support bracket.
    Note
    (x2) push pins
  47. 3rd row/rear HVAC system only: Remove the foam HVAC ducting covering the charger access panel.
  48. Remove the LH side knee airbag.
    Note
    (x1) airbag connector, (x2) 10 mm Nyloc nuts
  49. Remove the top pad LH and RH vent covers.
  50. Remove the recirculation hood.
    Note
    (x2) clips
  51. Remove the front passenger side front airbag bolts.
    Note
    (x2) bolts, 10mm, 10 Nm
  52. Disconnect the airbag connectors.
    Note
    (x3) connectors. Release locking tab, and then release the connector.
  53. On the LH side, remove the lower binnacle cover trim.
  54. Remove the (x2) top pad fasteners that were covered by the lower binnacle cover.
  55. Remove (x1) T20 screw of each side of the top pad corners.
    Note
    (x2) T20 screws
  56. Remove the top pad from the vehicle and disconnect the ground strap. Recommend assistance.
    Note
    (x1) ground strap (x1) harness edge clip
  57. Remove the warranty label sticker and clean off its residue with S.E.M. solve.
  58. Remove and discard the screws for the access cover on the charger.
    Note
    (x11) T20 patch screws. Tamper proof tape.
  59. Verify no high voltage is present.
    Warning
    Measure B+ to B-, B+ to ground, and B- to ground. Make sure to wear proper PPE. Verify you are using a proper ground and not a coated surface. If voltage is greater than 10V, pack contactors are not open or welded. Stop work and contact Service Engineering.
  60. Remove the upper steering column cover trim.
    Note
    (x2) mounting clips
  61. Remove the instrument cluster bezel from the IP carrier.
    Note
    (x4) screws, T20, 2.3 Nm
  62. Remove the LH trim finisher.
    Note
    (x3) T20 bolts
  63. Remove the center trim finisher.
    Note
    (x2) T20 bolts
  64. Remove the RH trim finisher.
    Note
    (x2) T20 bolts
  65. Remove the steering wheel airbag.
    Note
    (x2) T30 screws, (x3) electrical connectors
  66. Remove the bolt that secures the steering wheel to the column.
    Note
    (x1) patch bolt, 10 mm Allen, 80 Nm. Discard after removal.
  67. Remove the metal "U" plate under the steering wheel.
    Note
    (x2) T20 screws
  68. Remove the steering wheel column cover.
    Note
    Column cover slides on and off.
  69. With the steering column cover in your lap, remove the safety pin from the yellow connector.
    Note
    A new safety clip will need to be ordered.
  70. Disconnect the (x2) gray electrical connectors for the power adjust steering column.
    Note
    (x2) electrical connectors
  71. Disconnect the steering half shaft from the steering column assembly.
    Note
    (x1) 13 mm bolt
  72. Remove the (x4) 13 mm mounting hardware for the steering column assembly to the IP cross car beam.
  73. Disconnect the steering column assembly from the steering half shaft and remove from the vehicle.
  74. Remove and disconnect the MCU electrical connectors. Remove from vehicle. Place the MCU on an anti-static mat.
    Note
    (x4) T25 screws
  75. Remove the (x4) T20 screws for the instrument cluster. Place them on an anti-static mat.
    Note
    (x4) T20 screws, (x2) electrical connectors
  76. Remove the LH sun visor bezel.
    Note
    The bezel clips in.
  77. Remove the LH upper A pillar trim.
    Note
    (x1) 13 mm Nyloc nut, (x1) T20 screw, (x2) 10 mm bolts, (x2) electrical connectors
  78. Remove the RH visor bezel.
    Note
    (x7) clips
  79. Remove the RH upper A-pillar trim.
    Note
    (x2) electrical connectors, (x2) 10 mm, (x1) 13 mm, (x1) T20
  80. Remove the (x4) T20 screws for the defrost grill and remove from the vehicle.
    Note
    (x4) T20 screws
  81. Remove the IP carrier speakers.
    Note
    (x6) screws, T20, 2 Nm, (x3) electrical connectors
  82. Remove all of the contents from inside the center console assembly.
    Note
    Cup holders, rubber center console mat.
  83. Remove the rear center console cup holder trim.
    Note
    Unclips in an upward motion.
  84. Remove the rear center console vent bezel and disconnect the (x2) USB module connectors.
    Note
    Vent bezel clips in.
  85. Remove the rear center console trim panel. (x6) electrical connectors.
    Note
    Trim panel clips in.
  86. Remove all (x9) mounting fasteners from the center console.
    Note
    (x6) 10 mm bolts, (x3) T25 screws
  87. Remove the center console from the vehicle.
    Note
    Recommend assistance.
  88. Remove the IP carrier from the cross car beam.
    Note
    (x13) screws, T20, 2 Nm, (x1) clip. Release clip securing speaker connection on underside of carrier. Recommend assistance.
  89. Remove the cross car beam.
    Note
    (x10) bolts, 13 mm, 27 Nm. Recommend assistance.
  90. On the driver side, fold the carpeting to access the harness connectors.
  91. Disconnect all the electrical connectors for the IP carrier cross car beam and harness edge clips.
    Note
    (x34) electrical connectors, (x3) wire harness mounting cages, (x1) harness clip
  92. Release the center front HVAC outlet duct from the bottom of the HVAC box, but do not attempt to remove from the vehicle.
  93. Release both of the front 2nd row passenger ducts front the bottom of the HVAC box, but do not attempt to remove the vents from the vehicle.
  94. Remove the IP cross car beam from the vehicle.
    Note
    Recommend assistance.
  95. Disconnect the PTC heater HV cable connector from the forward junction box (FJB).
    Note
    (x1) locking harness connector
  96. Route the PTC HV cable into the cabin.
    Note
    Push the HV cable grommet through the bulkhead towards the interior of the vehicle and carefully pull the HV cable through the bulkhead into the cabin of the vehicle.
  97. Remove the wiper motor assembly.
    Note
    (x3) bolts, 10 mm, 9 Nm, (x1) electrical connector
  98. Remove the (x4) 13 mm fasteners from the center cowl windshield wiper assembly support bracket and release wiring harness clip.
    Note
    (x2) 13 mm nuts, (x2) 13 mm bolts
  99. Remove the (x2) T30 bolts from the TXV valve separating the TXV from the bulkhead.
  100. Disconnect the harness from the HVAC assembly.
    Note
    (x3) connectors, (x3) clips
  101. Remove the bolts that secure the HVAC assembly to the cowl.
    Note
    (x2) bolts, 10 mm, 6 Nm
  102. Remove the nuts that secure the HVAC assembly to the bulkhead.
    Note
    (x5) nuts, 10 mm, 6 Nm
  103. Release the HVAC drain hose from the nipple on the HVAC assembly while removing the HVAC assembly from the vehicle.
    Note
    Recommend assistance. Plug pipe connections to prevent ingress of moisture or dirt. Place suitable absorbent material around the affected area to absorb any possible fluid spillage.

Installation

  1. Install the new HVAC box assembly into the vehicle and install the (x2) 10 mm bolts onto the interior cowl holding the HVAC in place.
    Note
    (x2) 10 mm bolts. Recommend assistance.
  2. Connect the HVAC drain tube to the HVAC box assembly.
    Note
    Verify the drain hose is fully installed.
  3. Install the fasteners securing the HVAC assembly to the body.
    Note
    (x5) nuts, 10 mm, 6 Nm, (x2) bolts, 10 mm, 6 Nm
  4. Install the PTC heater HV cable into the bulk head of the vehicle.
    Note
    Make sure the rubber seal seated before continuing to the next step.
  5. Connect the PTC heater HV cable into the front HVJB.
    Note
    (x1) locking harness connection in the frunk area of the vehicle.
  6. Connect the electrical connectors to the HVAC assembly.
    Note
    (x3) electrical connectors, (x3) clips
  7. Position the cross car beam into the vehicle for installation.
    Note
    Recommend assistance. Exercise caution when installing the cross car beam.
  8. Make the metal IP cage harness connectors and edge clip installations.
    Note
    (x34) electrical connectors, (x3) wire harness mounting cages, (x1) harness clip
  9. Hand start the metal IP carrier mounting hardware.
    Note
    (x10) 13 mm fasteners
  10. Torque the metal IP cross brace to 27 Nm.
    Note
    (x10) 13 mm bolts
  11. Install the 2nd row passenger ducts.
  12. Install the front HVAC outlet duct.
  13. Place the IP carrier plastic subassembly into vehicle, line it up and fit into position. Recommend assistance.
    Note
    Reconnect (x1) connector at the top center of the dash.
  14. Thread the main wire harness and all the MCU connectors through the empty MCU area so they are ready for MCU reinstallation.
  15. Tuck in and anchor the LH and RH corners of the IP carrier plastic subassembly before you start installing the fasteners, and then install the fasteners.
    Note
    (x13) T20 screws
  16. Install the IP speakers.
    Note
    (x6) screws, T20, 2 Nm, (x3) connectors. Pull the IP carrier forward for better access for speakers.
  17. Install the defrost grill assembly.
    Note
    (x4) screws, T20, 2 Nm, (x2) clips
  18. Reconnect (x2) connectors, and then snap the instrument cluster into place. Install the (x4) fasteners.
    Note
    (x4) T20 screws
  19. Install the LH upper A pillar.
    Note
    (x1) nut, 13 mm, 8 Nm (x1) screw, T20, 2 Nm, (x2) bolts, 10 mm, 5 Nm, (x2) electrical connectors
  20. RH side lower A-pillar area: Connect and install the electrical connector bracket to the vehicle.
    Note
    (x4) electrical connectors, (x1) bracket install
  21. LH side lower A-pillar area: Connect and install the electrical connector bracket to the vehicle and tuck the carpet back afterward.
    Note
    (x4) electrical connectors, (x1) bracket install
  22. Double check that all of the electrical connectors are made before installing the center console.
  23. Place center console inside the vehicle and make the (x6) electrical connectors for the center console assembly.
    Note
    Recommend assistance.
  24. Install the center console mounting hardware and torque to spec. Torque everything to 2.5 Nm. Torque the washered 10 mm bolts to 7 Nm
    Note
    (x1) T25 screw, (x2) T20 screws (x2), 10 mm patch bolts (x2), washer 10 mm patch bolts, (x2) 32 mm long 10 mm bolts
  25. Install the steering column assembly to the IP cross car beam. Torque the upper nuts to 30 Nm. Torque the lower bolts to 17 Nm.
    Note
    (x2) 13 mm bolts, (x2) 13 mm nuts
  26. Attach the steering half shaft to the adjustable steering column. Torque to 30 Nm.
  27. Insert a new safety pin into the yellow steering column connector, and then make the connection to the steering wheel column cover.
  28. Install the steering column cover onto the steering column after the yellow connection has been made.
    Note
    Cover slides on the column.
  29. Reconnect the (x2) gray electrical connectors for the steering wheel height adjustment.
    Note
    (x2) gray electrical connectors
  30. Connect the MCU electrical connectors, and then install the (x4) T25 mounting screws.
    Note
    (x4) T25 screws, (x14) MCU electrical connectors
  31. Install the RH side IP finisher trim assembly.
    Note
    (x2) T20 screws
  32. Install the LH side center IP finisher trim assembly.
    Note
    (x2) T20 screws
  33. Install the LH side outer finisher trim assembly.
    Note
    (x3) T20 screws
  34. Install the IC trim bezel.
    Note
    (x4) T20 screws
  35. Secure the steering column gap hider trim to the IC bezel.
    Note
    (x2) clips
  36. Install the LH upper A-pillar trim.
    Note
    (x2) electrical connectors, (x2) 10 mm, (x1) 13 mm, (x1) T20 screw
  37. Install the LH sun visor bezel.
    Note
    The bezel clips in.
  38. Install the RH upper A-pillar trim.
    Note
    (x2) electrical connectors, (x2) 10 mm, (x1) 13 mm, (x1) T20
  39. Install the RH sun visor bezel
    Note
    The bezel clips in.
  40. Install the foam flooring into the right side of the vehicle, and then fold the carpeting back into place afterward.
    Note
    (x2) foam flooring panels, (x2) screws on flex retaining clips, (x2) fur tree push clips
  41. In the frunk area: Attach the TXV valve to the A/C line coming out of the bulk head. Torque to 6 Nm.
    Note
    (x2) T30 machine screws
  42. Install the windshield wiper assembly support bracket into the vehicle.
    Note
    (x2) 13 mm nuts, (x2) 13 mm bolts, (x1) harness squeeze clip
  43. Install the windshield wiper motor assembly into the vehicle.
    Note
    (x1) electrical connectors, (x3) 10 mm bolts
  44. In the trunk: Install the "L" shaped charger access panel back into place in the vehicle. Torque 2 Nm.
    Note
    (x1) T20 patch screws
  45. Install the charger access panel warranty void sticker onto the charger.
  46. Install the top pad into the vehicle. Recommend assistance.
    Note
    (x1) ground strap
  47. Install the steering wheel into the vehicle. Torque to 80 Nm.
    Note
    (x1) new patch 10 mm Allen bolt.
  48. Install the driver airbag into the steering wheel assembly. Torque to 7 Nm.
    Note
    (x3) electrical connectors
  49. Install the driver knee airbag into the vehicle. Torque to 10 Nm.
    Note
    (x2) 10 mm Nyloc nuts, (x1) locking electrical connectors
  50. Install the (x3) front passenger side airbag electrical connectors.
    Note
    (x3) locking electrical connectors, (x2) harness edge clips
  51. Install the (x2) 10 mm bolts for the front passenger side airbag. Torque to 10 Nm.
    Note
    (x2) 10 mm bolts
  52. Attach the under MCU data cable harness edge clip onto the plastic IP cage.
  53. Connect First Responder Loop, and then the 12V negative terminal.
    Note
    (x1) connector, (x1) nut, 10mm, 5 Nm
  54. Recharge the refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  55. Install the rear HVAC foam ducting into the vehicle.
  56. Install the LH side support bracket.
    Note
    (x2) larger push pins
  57. Install the LH rear mid C-pillar trim into the vehicle.
    Note
    (x1) 12V electrical connector
  58. Install the trim into the LH side mid C-pillar.
  59. Install the upper C-pillar trim into the vehicle.
    Note
    (x2) T20 screws, (x1) T25 patch screw
  60. Install the rear trunk waterfall carpeted trim panel.
    Note
    (x4) larger push pin fasteners
  61. Install the rear trunk trough carpet.
  62. Install the rear trunk sill trim.
    Note
    (x2) T25 patch screws
  63. Install the mid C-pillar trim into the trunk area of the vehicle.
    Note
    (x2) T20 screws
  64. Install the RH trunk sill side trim.
    Note
    (x4) clips
  65. Install the rear load floor.
  66. Close the rear hatch of the vehicle.
  67. Install the LH side lower C-pillar.
    Note
    (x1) T25 patch screw.
  68. Return both of the second row seats out of the "easy entry" mode.
    Note
    Switch on the back of the second row seating.
  69. Install the LH side mid A-pillar into the vehicle.
    Note
    (x1) T25 patch screw
  70. Install the LH side lower A-pillar into the vehicle.
  71. Install the LH side lower weather stripping back into the vehicle.
  72. Install the LH rear lower B-pillar trim into the vehicle.
    Note
    (x1) T25 patch screw
  73. Install the LH welcome plate.
    Note
    (x8) clips
  74. Install the RH side mid A-pillar into the vehicle.
    Note
    (x1) T25 patch screw
  75. Install the RH side lower A-pillar into the vehicle.
  76. Install the RH side lower weather stripping back into the vehicle.
  77. Install the RH rear lower B-pillar trim into the vehicle.
    Note
    (x1) T25 patch screw
  78. Install the RH welcome plate.
    Note
    (x8) clips
  79. Remove the A/C machine from the vehicle.
    Note
    Install the A/C fill port covers.
  80. Install the RH recirculation NVH hood.
    Note
    (x2) clips. If vehicle is equipped with DAS 2.0 and the module was removed in order to access the front passenger airbag bolts, then reinstall the DAS 2.0 module.
  81. Install the glove box assembly.
    Note
    (x3) connectors, (x6) screws, T20, 2.3 Nm
  82. Install the RH instrument panel lower assembly.
    Note
    (x13) clips. Replace any damaged or missing clips prior to installation.
  83. Install the (x1) T20 screw on the RH side for the top pad to the plastic IP cage.
    Note
    (x1) T20 screw
  84. Install the top pad vent cover to the RH side of the vehicle.
  85. Install the RH IP end cap.
    Note
    (x5) clips
  86. Install the RH side lower IP kick panel.
    Note
    (x1) electrical connector, (x2) teal mounting tabs
  87. Install the carpeted lower center console trim onto the RH side of vehicle.
  88. Install the upper center console trim on the RH side of the vehicle.
  89. Install the lower glove box trim.
    Note
    (x6) clips. Replace any damaged or missing clips prior to installation.
  90. Install the (x2) T20 screws for the bionary cover area and install the cover. (x2) T20 screws and install the cover afterward.
    Note
    (x2) T20 screws
  91. Install the metal horse shoe trim cover onto the steering column.
    Note
    (x2) T20 screws
  92. Install the top pad vent cover onto the LH side.
  93. Install the LH side lower IP kick panel into the vehicle. Make sure the vent lines up when installing the trim cover.
    Note
    (x1) electrical connector, (x2) teal attachment clips
  94. Install the driver side lower carpeted center console trim panel.
  95. Install the upper LH side center console trim onto the center console.
  96. Install the LH lower IP trim panel.
    Note
    (x9) clips
  97. Install the LH side IP end cap.
  98. In the frunk area: Install the HVAC box ducting into the vehicle.
    Note
    (x1) push pin
  99. Install the center cowl cover assembly.
    Note
    (x5) push clips, (x1) harness edge clip, (x1) windshield washer hose, (x1) cowl drain tube
  100. Install both outer side cowl covers.
    Note
    (x2) cowl covers
  101. Install the HEPA filter housing.
  102. Install the underhood storage unit.
    Note
    (x20) 10 mm bolts
  103. Install the frunk carpet.
    Note
    (x2) electrical connectors
  104. Install the windshield wipers.
    Note
    (x3) 17 mm nuts
  105. Install the underhood aprons.
    Note
    (x4) aprons
  106. Close the hood.
  107. Install the rear center console trim panel, and install the electrical connectors.
    Note
    (x6) electrical connectors console trim clips in.
  108. Install the center console vent assembly into the rear of the center console.
    Note
    (x2) electrical connectors console trim clips in.
  109. Install the rear center console cup holder plastic trim back onto the front of the cup holder assembly.
    Note
    Trim installs in a downward motion.
  110. Put all the items that were in the center console back into the storage area.
    Note
    Cup holders, etc.
  111. Install the carpeted floor mats.
    Note
    (x2) pc.
  112. Calibrate the rear doors.
  113. Close the RH front door.
  114. Install a FW package to the vehicle.