15/12/2023 11:33:18
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
-
Use the vehicle touchscreen to
open the hood, the rear hatch, and all of the doors of the vehicle.
NoteWalk around and open the hood.
-
Remove the underhood
aprons.
Note(x4) aprons; LH and RH aprons have (x1) clip each.
- Recover the refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
-
Move the driver and front
passenger seats rearward.
NoteEasier to remove the center console later in this procedure.
-
Open the glove box.
NotePress the button on the RH side of MCU bezel.
-
Remove the lower glove box
trim.
-
Remove the upper glove box
trim.
-
Remove the glove box from the
vehicle.
Note(x6) T20 screws, (x3) electrical connectors
-
Remove both side IP side end
caps.
Note(x2) pc.
-
Remove the carpeted floor mats
from both front seating areas.
-
Release the upper leather side
trims of the LH and RH center console.
-
Remove the RH and LH center
console carpeted closeout panels.
-
Remove both rear welcome plates.
-
Remove the LH side B-Pillar rear
trim.
Note(x1) T25 patch screw
-
Partially remove the LH side
lower A-pillar weather seal.
-
Remove the LH lower A-pillar
trim.
-
Remove the LH mid A-pillar trim
from the vehicle.
Note(x1) T25 patch screws
-
Remove the driver knee
bolster.
Note(x2) screws, (x9) clips, T20, 2.3 Nm
-
Remove the lower IP kick panel
trim on the left side.
Note(x1) electrical connector, (x2) teal mounting tabs
-
Remove the RH rear B-pillar
trim.
Note(x1) T25 patch screw
- Partially remove the RH side lower A-pillar seal.
- Remove the RH side lower A-pillar trim.
-
Remove the right side mid
A-pillar trim from the vehicle.
Note(x1) T25 patch screw
-
Remove the RH side lower IP kick
panel trim cover.
Note(x1) electrical connection, (x2) teal mounting
-
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
- Move the second row seat into “easy” entry mode.
-
Remove LH lower C-pillar trim
(x1) T25 patch screw, and then remove the lower C-pillar from the vehicle.
Note(x1) T25 screw
-
Remove the LH trunk sill side
trim.
Note(x4) clips
-
Release the (x2) screws that
secure the LH mid C-Pillar trim, and then remove the trim from the vehicle.
Note(x2) T20 screws
-
Remove the rear load floor.
-
Remove the trunk sill trim.
Note(x4) clips, (x2) patch bolts, T25, 2.5 Nm. Discard after removal.
-
Remove the underhood storage unit
carpet liner.
Note(x2) electrical connectors
-
Remove the underhood storage
unit.
Note(x20) 10 mm bolts
-
Remove the HEPA filter.
NoteLift up from bottom and pull out.
-
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
-
Remove both sides outer cowl
covers.
Note(x2) plastic anchor clips per side.
-
Remove the center cowl
section.
Note(x5) push pins, (x1) harness edge clip (x1), washer hose one-way valve
-
Remove the HEPA filter
duct.
Note(x1) clip
- Power down the vehicle.
-
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.
-
Remove the LH upper C-pillar
trim.
Note(x3) T20 screws, (x1) T25 patch screw
-
Remove the trim from the LH side
mid C-pillar trim.
-
Remove the (x4) push pins from
the rear trunk water fall carpeting.
-
Remove the lower trunk trough
trim.
-
Remove the LH side C-pillar trunk
side trim panel.
Note(x1) 12v harness connector
-
Remove the load floor support
bracket.
Note(x2) push pins
-
3rd row/rear HVAC
system only: Remove the foam HVAC ducting covering the charger
access panel.
-
Remove the LH side knee
airbag.
Note(x1) airbag connector, (x2) 10 mm Nyloc nuts
-
Remove the top pad LH and RH vent
covers.
-
Remove the recirculation
hood.
Note(x2) clips
-
Remove the front passenger side
front airbag bolts.
Note(x2) bolts, 10mm, 10 Nm
-
Disconnect the airbag
connectors.
Note(x3) connectors. Release locking tab, and then release the connector.
-
On the LH side, remove the lower
binnacle cover trim.
-
Remove the (x2) top pad fasteners
that were covered by the lower binnacle cover.
-
Remove (x1) T20 screw of each
side of the top pad corners.
Note(x2) T20 screws
-
Remove the top pad from the
vehicle and disconnect the ground strap. Recommend assistance.
Note(x1) ground strap (x1) harness edge clip
-
Remove the warranty label sticker
and clean off its residue with S.E.M. solve.
-
Remove and discard the screws for
the access cover on the charger.
Note(x11) T20 patch screws. Tamper proof tape.
-
Verify no high voltage is
present.
WarningMeasure 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.
-
Remove the upper steering column
cover trim.
Note(x2) mounting clips
-
Remove the instrument cluster
bezel from the IP carrier.
Note(x4) screws, T20, 2.3 Nm
-
Remove the LH trim
finisher.
Note(x3) T20 bolts
-
Remove the center trim
finisher.
Note(x2) T20 bolts
-
Remove the RH trim
finisher.
Note(x2) T20 bolts
-
Remove the steering wheel
airbag.
Note(x2) T30 screws, (x3) electrical connectors
-
Remove the bolt that secures the
steering wheel to the column.
Note(x1) patch bolt, 10 mm Allen, 80 Nm. Discard after removal.
-
Remove the metal "U" plate under
the steering wheel.
Note(x2) T20 screws
-
Remove the steering wheel column
cover.
NoteColumn cover slides on and off.
-
With the steering column cover in
your lap, remove the safety pin from the yellow connector.
NoteA new safety clip will need to be ordered.
-
Disconnect the (x2) gray
electrical connectors for the power adjust steering column.
Note(x2) electrical connectors
-
Disconnect the steering half
shaft from the steering column assembly.
Note(x1) 13 mm bolt
-
Remove the (x4) 13 mm mounting
hardware for the steering column assembly to the IP cross car beam.
- Disconnect the steering column assembly from the steering half shaft and remove from the vehicle.
-
Remove and disconnect the MCU
electrical connectors. Remove from vehicle. Place the MCU on an anti-static
mat.
Note(x4) T25 screws
-
Remove the (x4) T20 screws for
the instrument cluster. Place them on an anti-static mat.
Note(x4) T20 screws, (x2) electrical connectors
-
Remove the LH sun visor
bezel.
NoteThe bezel clips in.
-
Remove the LH upper A pillar
trim.
Note(x1) 13 mm Nyloc nut, (x1) T20 screw, (x2) 10 mm bolts, (x2) electrical connectors
-
Remove the RH visor bezel.
Note(x7) clips
-
Remove the RH upper A-pillar
trim.
Note(x2) electrical connectors, (x2) 10 mm, (x1) 13 mm, (x1) T20
-
Remove the (x4) T20 screws for
the defrost grill and remove from the vehicle.
Note(x4) T20 screws
-
Remove the IP carrier
speakers.
Note(x6) screws, T20, 2 Nm, (x3) electrical connectors
-
Remove all of the contents from
inside the center console assembly.
NoteCup holders, rubber center console mat.
-
Remove the rear center console
cup holder trim.
NoteUnclips in an upward motion.
-
Remove the rear center console
vent bezel and disconnect the (x2) USB module connectors.
NoteVent bezel clips in.
-
Remove the rear center console
trim panel. (x6) electrical connectors.
NoteTrim panel clips in.
-
Remove all (x9) mounting
fasteners from the center console.
Note(x6) 10 mm bolts, (x3) T25 screws
-
Remove the center console from
the vehicle.
NoteRecommend assistance.
-
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.
-
Remove the cross car beam.
Note(x10) bolts, 13 mm, 27 Nm. Recommend assistance.
-
On the driver side, fold the
carpeting to access the harness connectors.
-
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
-
Release the center front HVAC
outlet duct from the bottom of the HVAC box, but do not attempt to remove from the
vehicle.
-
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.
-
Remove the IP cross car beam from
the vehicle.
NoteRecommend assistance.
-
Disconnect the PTC heater HV
cable connector from the forward junction box (FJB).
Note(x1) locking harness connector
-
Route the PTC HV cable into the
cabin.
NotePush 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.
-
Remove the wiper motor
assembly.
Note(x3) bolts, 10 mm, 9 Nm, (x1) electrical connector
-
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
-
Remove the (x2) T30 bolts from
the TXV valve separating the TXV from the bulkhead.
-
Disconnect the harness from the
HVAC assembly.
Note(x3) connectors, (x3) clips
-
Remove the bolts that secure the
HVAC assembly to the cowl.
Note(x2) bolts, 10 mm, 6 Nm
-
Remove the nuts that secure the
HVAC assembly to the bulkhead.
Note(x5) nuts, 10 mm, 6 Nm
-
Release the HVAC drain hose from
the nipple on the HVAC assembly while removing the HVAC assembly from the
vehicle.
NoteRecommend 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
-
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.
-
Connect the HVAC drain tube to
the HVAC box assembly.
NoteVerify the drain hose is fully installed.
-
Install the fasteners securing
the HVAC assembly to the body.
Note(x5) nuts, 10 mm, 6 Nm, (x2) bolts, 10 mm, 6 Nm
-
Install the PTC heater HV cable
into the bulk head of the vehicle.
NoteMake sure the rubber seal seated before continuing to the next step.
-
Connect the PTC heater HV cable
into the front HVJB.
Note(x1) locking harness connection in the frunk area of the vehicle.
-
Connect the electrical connectors
to the HVAC assembly.
Note(x3) electrical connectors, (x3) clips
-
Position the cross car beam into
the vehicle for installation.
NoteRecommend assistance. Exercise caution when installing the cross car beam.
-
Make the metal IP cage harness
connectors and edge clip installations.
Note(x34) electrical connectors, (x3) wire harness mounting cages, (x1) harness clip
-
Hand start the metal IP carrier
mounting hardware.
Note(x10) 13 mm fasteners
-
Torque the metal IP cross brace
to 27 Nm.
Note(x10) 13 mm bolts
-
Install the 2nd row passenger
ducts.
-
Install the front HVAC outlet
duct.
-
Place the IP carrier plastic
subassembly into vehicle, line it up and fit into position. Recommend
assistance.
NoteReconnect (x1) connector at the top center of the dash.
-
Thread the main wire harness and
all the MCU connectors through the empty MCU area so they are ready for MCU
reinstallation.
-
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
-
Install the IP speakers.
Note(x6) screws, T20, 2 Nm, (x3) connectors. Pull the IP carrier forward for better access for speakers.
-
Install the defrost grill
assembly.
Note(x4) screws, T20, 2 Nm, (x2) clips
-
Reconnect (x2) connectors, and
then snap the instrument cluster into place. Install the (x4) fasteners.
Note(x4) T20 screws
-
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
-
RH side lower A-pillar area:
Connect and install the electrical connector bracket to the vehicle.
Note(x4) electrical connectors, (x1) bracket install
-
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
- Double check that all of the electrical connectors are made before installing the center console.
-
Place center console inside the
vehicle and make the (x6) electrical connectors for the center console assembly.
NoteRecommend assistance.
-
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
-
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
-
Attach the steering half shaft to
the adjustable steering column. Torque to 30 Nm.
-
Insert a new safety pin into the
yellow steering column connector, and then make the connection to the steering
wheel column cover.
-
Install the steering column cover
onto the steering column after the yellow connection has been made.
NoteCover slides on the column.
-
Reconnect the (x2) gray
electrical connectors for the steering wheel height adjustment.
Note(x2) gray electrical connectors
-
Connect the MCU electrical
connectors, and then install the (x4) T25 mounting screws.
Note(x4) T25 screws, (x14) MCU electrical connectors
-
Install the RH side IP finisher
trim assembly.
Note(x2) T20 screws
-
Install the LH side center IP
finisher trim assembly.
Note(x2) T20 screws
-
Install the LH side outer
finisher trim assembly.
Note(x3) T20 screws
-
Install the IC trim bezel.
Note(x4) T20 screws
-
Secure the steering column gap
hider trim to the IC bezel.
Note(x2) clips
-
Install the LH upper A-pillar
trim.
Note(x2) electrical connectors, (x2) 10 mm, (x1) 13 mm, (x1) T20 screw
-
Install the LH sun visor
bezel.
NoteThe bezel clips in.
-
Install the RH upper A-pillar
trim.
Note(x2) electrical connectors, (x2) 10 mm, (x1) 13 mm, (x1) T20
-
Install the RH sun visor
bezel
NoteThe bezel clips in.
-
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
-
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
-
Install the windshield wiper
assembly support bracket into the vehicle.
Note(x2) 13 mm nuts, (x2) 13 mm bolts, (x1) harness squeeze clip
-
Install the windshield wiper
motor assembly into the vehicle.
Note(x1) electrical connectors, (x3) 10 mm bolts
-
In the trunk: Install the "L"
shaped charger access panel back into place in the vehicle. Torque 2 Nm.
Note(x1) T20 patch screws
-
Install the charger access panel
warranty void sticker onto the charger.
-
Install the top pad into the
vehicle. Recommend assistance.
Note(x1) ground strap
-
Install the steering wheel into
the vehicle. Torque to 80 Nm.
Note(x1) new patch 10 mm Allen bolt.
-
Install the driver airbag into
the steering wheel assembly. Torque to 7 Nm.
Note(x3) electrical connectors
-
Install the driver knee airbag
into the vehicle. Torque to 10 Nm.
Note(x2) 10 mm Nyloc nuts, (x1) locking electrical connectors
-
Install the (x3) front passenger
side airbag electrical connectors.
Note(x3) locking electrical connectors, (x2) harness edge clips
-
Install the (x2) 10 mm bolts for
the front passenger side airbag. Torque to 10 Nm.
Note(x2) 10 mm bolts
-
Attach the under MCU data cable
harness edge clip onto the plastic IP cage.
-
Connect First Responder Loop, and
then the 12V negative terminal.
Note(x1) connector, (x1) nut, 10mm, 5 Nm
- Recharge the refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
-
Install the rear HVAC foam
ducting into the vehicle.
-
Install the LH side support
bracket.
Note(x2) larger push pins
-
Install the LH rear mid C-pillar
trim into the vehicle.
Note(x1) 12V electrical connector
-
Install the trim into the LH side
mid C-pillar.
-
Install the upper C-pillar trim
into the vehicle.
Note(x2) T20 screws, (x1) T25 patch screw
-
Install the rear trunk waterfall
carpeted trim panel.
Note(x4) larger push pin fasteners
-
Install the rear trunk trough
carpet.
-
Install the rear trunk sill
trim.
Note(x2) T25 patch screws
-
Install the mid C-pillar trim
into the trunk area of the vehicle.
Note(x2) T20 screws
-
Install the RH trunk sill side
trim.
Note(x4) clips
-
Install the rear load
floor.
- Close the rear hatch of the vehicle.
-
Install the LH side lower
C-pillar.
Note(x1) T25 patch screw.
-
Return both of the second row
seats out of the "easy entry" mode.
NoteSwitch on the back of the second row seating.
-
Install the LH side mid A-pillar
into the vehicle.
Note(x1) T25 patch screw
-
Install the LH side lower
A-pillar into the vehicle.
-
Install the LH side lower weather
stripping back into the vehicle.
-
Install the LH rear lower
B-pillar trim into the vehicle.
Note(x1) T25 patch screw
-
Install the LH welcome
plate.
Note(x8) clips
-
Install the RH side mid A-pillar
into the vehicle.
Note(x1) T25 patch screw
- Install the RH side lower A-pillar into the vehicle.
- Install the RH side lower weather stripping back into the vehicle.
-
Install the RH rear lower
B-pillar trim into the vehicle.
Note(x1) T25 patch screw
-
Install the RH welcome
plate.
Note(x8) clips
-
Remove the A/C machine from the
vehicle.
NoteInstall the A/C fill port covers.
-
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.
-
Install the glove box
assembly.
Note(x3) connectors, (x6) screws, T20, 2.3 Nm
-
Install the RH instrument panel
lower assembly.
Note(x13) clips. Replace any damaged or missing clips prior to installation.
-
Install the (x1) T20 screw on the
RH side for the top pad to the plastic IP cage.
Note(x1) T20 screw
-
Install the top pad vent cover to
the RH side of the vehicle.
-
Install the RH IP end cap.
Note(x5) clips
-
Install the RH side lower IP kick
panel.
Note(x1) electrical connector, (x2) teal mounting tabs
-
Install the carpeted lower center
console trim onto the RH side of vehicle.
- Install the upper center console trim on the RH side of the vehicle.
-
Install the lower glove box
trim.
Note(x6) clips. Replace any damaged or missing clips prior to installation.
-
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
-
Install the metal horse shoe trim
cover onto the steering column.
Note(x2) T20 screws
- Install the top pad vent cover onto the LH side.
-
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
-
Install the driver side lower
carpeted center console trim panel.
-
Install the upper LH side center
console trim onto the center console.
-
Install the LH lower IP trim
panel.
Note(x9) clips
- Install the LH side IP end cap.
-
In the frunk area: Install the
HVAC box ducting into the vehicle.
Note(x1) push pin
-
Install the center cowl cover
assembly.
Note(x5) push clips, (x1) harness edge clip, (x1) windshield washer hose, (x1) cowl drain tube
-
Install both outer side cowl
covers.
Note(x2) cowl covers
-
Install the HEPA filter
housing.
-
Install the underhood storage
unit.
Note(x20) 10 mm bolts
-
Install the frunk carpet.
Note(x2) electrical connectors
-
Install the windshield
wipers.
Note(x3) 17 mm nuts
-
Install the underhood
aprons.
Note(x4) aprons
- Close the hood.
-
Install the rear center console
trim panel, and install the electrical connectors.
Note(x6) electrical connectors console trim clips in.
-
Install the center console vent
assembly into the rear of the center console.
Note(x2) electrical connectors console trim clips in.
-
Install the rear center console
cup holder plastic trim back onto the front of the cup holder assembly.
NoteTrim installs in a downward motion.
-
Put all the items that were in
the center console back into the storage area.
NoteCup holders, etc.
-
Install the carpeted floor
mats.
Note(x2) pc.
- Calibrate the rear doors.
- Close the RH front door.
- Install a FW package to the vehicle.