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Heating, Ventilation and Air Conditioning: Removal & Installation Cadillac STS I

Automatic HVAC System 1 illustration ~7319 words

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197548-S05121562292005101200000) in Engine Controls-3.6L.
  3. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Power Steering and Air Conditioning»(ref-197574-S17648090552005101200000) in Engine Mechanical-3.6L.
  4. Reposition power steering reservoir aside. Refer to «Remote Power Steering Fluid Reservoir Replacement (LH2)»(ref-197600-S28414548482005101200000) or «Remote Power Steering Fluid Reservoir Replacement (LY7)»(ref-197600-S39984550642005101200000) .
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  6. Remove the LH wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  7. Remove the engine splash shield. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) .
  8. Remove the suction line bolt (1) at the compressor.
  9. Remove the discharge line bolt (2) at the compressor.
  10. Disconnect the A/C lines from the compressor.
  11. Disconnect the electrical connector from the compressor.
  12. Remove the compressor mounting bolts.
  13. Lower the vehicle.
  14. Rotate the compressor and remove from the vehicle.
  15. Replace the desiccant bag if the following conditions exist. Refer to «Desiccant Bag Replacement»(ref-197627-S15771112942005101200000) . Color of PAG oil is brown or black Presence of foreign substances
  16. If you are replacing the compressor, balance the compressor oil. Refer to «Compressor Oil Balancing»(ref-197627-S00068994752005101200000) .
  17. Remove and discard the O-ring seals from the compressor suction and discharge lines. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .

Installation Procedure

  1. Install the compressor.
  2. Raise and support the vehicle.
  3. Install the compressor mounting bolts.
  4. Tighten the compressor mounting bolts. Tighten: Tighten the stud to 25 N.m (18 lb ft).
  5. Connect the electrical connector.
  6. Install new O-ring seals to the line fittings. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  7. Connect the suction line to the compressor.
  8. Install the suction line bolt (1). Tighten: Tighten the bolt to 9.8 N.m (87 lb in).
  9. Connect the discharge line to the compressor
  10. Install the discharge line bolt (2). Tighten: Tighten the bolt to 9.8 N.m (87 lb in).
  11. Install the engine splash shield. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) .
  12. Install the LH wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  13. Lower the vehicle.
  14. Reposition and install the power steering reservoir. Refer to «Remote Power Steering Fluid Reservoir Replacement (LH2)»(ref-197600-S28414548482005101200000) or «Remote Power Steering Fluid Reservoir Replacement (LY7)»(ref-197600-S39984550642005101200000) .
  15. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Power Steering and Air Conditioning»(ref-197574-S17648090552005101200000) in Engine Mechanical-3.6L.
  16. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197548-S05121562292005101200000) in Engine Controls-3.6L.
  17. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  18. Using J 39400-A , leak test the fitting of the repaired or reinstalled component. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197553-S28415702912005101200000) in Engine Controls-4.6L.
  3. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Air Conditioning, Power Steering and Water Pump»(ref-197575-S11881171232005101200000) in Engine Mechanical-4.6L.
  4. Reposition power steering reservoir aside. Refer to «Remote Power Steering Fluid Reservoir Replacement (LH2)»(ref-197600-S28414548482005101200000) or «Remote Power Steering Fluid Reservoir Replacement (LY7)»(ref-197600-S39984550642005101200000) .
  5. Remove the cooling fan assembly. Refer to «Fan Replacement (LH2)»(ref-197587-S03651773992005101200000) or «Fan Replacement (LY7)»(ref-197587-S17673645992005101200000) or to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  7. Remove the LH wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  8. Remove the engine splash shield. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) .
  9. Remove the suction line bolt (1) from the compressor.
  10. Remove the discharge line bolt (2) from the compressor.
  11. Disconnect the suction and discharge line from the compressor.
  12. Remove the engine oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-197625-S29645980692005101200000) in Engine Mechanical-4.6L.
  13. Disconnect the electrical connector from the compressor.
  14. Remove the compressor mounting bolts.
  15. Lower the vehicle.
  16. Rotate the compressor and remove from the vehicle.
  17. Replace the desiccant bag if the following conditions exist. Refer to «Desiccant Bag Replacement»(ref-197627-S15771112942005101200000) . Color of PAG oil is brown or black Presence of foreign substances
  18. If you are replacing the compressor, balance the compressor oil. Refer to «Compressor Oil Balancing»(ref-197627-S00068994752005101200000) .
  19. Remove and discard the O-ring seals from the compressor suction and discharge lines. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  1. Install the compressor.
  2. Raise and support the vehicle.
  3. Install the compressor mounting bolts.
  4. Tighten the compressor mounting bolts. Tighten: Tighten the stud to 25 N.m (18 lb ft).
  5. Connect the electrical connector.
  6. Install the engine oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-197625-S29645980692005101200000) in Engine Mechanical-4.6L.
  7. Install new O-ring seals to the line fittings. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  8. Connect the suction line to the compressor.
  9. Install the suction line bolt (1). Tighten: Tighten the bolt to 9.8 N.m (87 lb in).
  10. Connect the discharge line to the compressor.
  11. Install the discharge line bolt (2). Tighten: Tighten the bolt to 9.8 N.m (87 lb in).
  12. Install the engine splash shield. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) .
  13. Install the LH wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  14. Lower the vehicle.
  15. Install the cooling fan assembly. Refer to «Fan Replacement (LH2)»(ref-197587-S03651773992005101200000) or «Fan Replacement (LY7)»(ref-197587-S17673645992005101200000) or to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  16. Reposition and install the power steering reservoir. Refer to «Remote Power Steering Fluid Reservoir Replacement (LH2)»(ref-197600-S28414548482005101200000) or «Remote Power Steering Fluid Reservoir Replacement (LY7)»(ref-197600-S39984550642005101200000) .
  17. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Air Conditioning, Power Steering and Water Pump»(ref-197575-S11881171232005101200000) in Engine Mechanical-4.6L.
  18. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197553-S28415702912005101200000) in Engine Controls-4.6L..
  19. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  20. Using J 39400-A , leak test the fitting of the repaired or reinstalled component. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure
  2. Remove the O-ring seal from the A/C refrigerant component.
  3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.
  4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
  5. Cap or tape the A/C refrigerant components.
  6. Discard the O-ring seal.
  1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
  2. Remove the cap or tape from the A/C refrigerant components.
  3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.
  4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
  5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
  6. The O-ring seal must be fully seated.
  7. Assemble the A/C components. Refer to the appropriate repair procedure.

A/C Line/Tube Connector Removal/Replacement

Tools Required

  1. J 39400-A Halogen Leak Detector. See «Special Tools»(ref-197627-S36369102382005101200000) .
  2. J 45689 A/C Quick Joint Tool. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Locate the A/C quick connect fitting locking tab access slots (1).
  3. Carefully insert J 45689 into the locking tab access slots. See «Special Tools»(ref-197627-S36369102382005101200000) .
  4. Gently press down on the locking tab until the quick connect fitting locking tab releases.
  5. Open and remove the quick connect fitting from the A/C refrigerant component.
  1. Install the A/C quick connect fitting to the A/C refrigerant component.
  2. Close the A/C quick connect fitting.
  3. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  4. Leak test the fittings of the component using J 39400-A . See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197548-S05121562292005101200000) in Engine Controls - 3.6L or to «Air Cleaner Assembly Replacement»(ref-197553-S28415702912005101200000) in Engine Controls - 4.6L.
  3. Remove the A/C quick connect fitting at the liquid line. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  5. Remove the front air deflector. Refer to «Air Deflector Replacement - Front»(ref-197566-S09922059352005101200000) .
  6. Remove the condenser tube to condenser retaining bolt.
  7. Disconnect the condenser tube from the fan shroud retainer clip.
  8. Disconnect the condenser tube from the condenser.
  9. Disconnect the condenser tube from the liquid line.
  10. Disconnect the A/C pressure sensor electrical connector.
  11. Remove the condenser tube.
  12. Remove the A/C pressure sensor (1).
  13. Remove and discard the O-rings.
  1. Install the new O-rings to the condenser tube. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  2. Install the A/C pressure sensor (1).
  3. Install the condenser tube.
  4. Connect the A/C pressure sensor electrical connector.
  5. Connect the condenser tube to the liquid line.
  6. Connect the condenser tube to the condenser.
  7. Connect the condenser tube to the fan shroud retainer clip.
  8. Install the condenser tube to condenser retaining bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  9. Install the front air deflector. Refer to «Air Deflector Replacement - Front»(ref-197566-S09922059352005101200000) .
  10. Lower the vehicle.
  11. Install the A/C quick connect fitting at the liquid line. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  12. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197548-S05121562292005101200000) in Engine Controls - 3.6L or to «Air Cleaner Assembly Replacement»(ref-197553-S28415702912005101200000) in Engine Controls - 4.6L.
  13. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  14. Using J 39400-A , leak test the fittings of the component. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  3. Remove the air deflector. Refer to «Air Deflector Replacement - Front»(ref-197566-S09922059352005101200000) .
  4. Remove the LH wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  5. Remove the engine splash shield. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) .
  6. Remove the bolt that holds the compressor discharge hose to the compressor.
  7. Separate the compressor discharge hose from the compressor.
  8. Remove the discharge hose bolt from the condenser.
  9. Separate the discharge line from the condenser.
  10. Remove the discharge hose.
  11. Remove and discard the O-ring seals.
  1. Install new O-rings. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  2. Install the discharge hose.
  3. Connect the discharge hose to the condenser.
  4. Install the discharge hose bolt. Tighten: Tighten the bolt to 5.4 N.m (48 lb in).
  5. Connect the discharge hose to compressor.
  6. Install the discharge hose bolt. Tighten: Tighten the bolt to 9.8 N.m (87 lb in).
  7. Install the engine splash shield. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) .
  8. Install the LH wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  9. Install the air deflector. Refer to «Air Deflector Replacement - Front»(ref-197566-S09922059352005101200000) .
  10. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  11. Using J 39400-A , leak test the fittings of the component. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  3. Remove the air deflector. Refer to «Air Deflector Replacement - Front»(ref-197566-S09922059352005101200000) .
  4. Remove the LH wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  5. Remove the engine splash shield. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) .
  6. Remove the discharge hose bolt at the compressor.
  7. Separate the compressor discharge hose from the compressor.
  8. Remove the discharge hose bolt from the condenser.
  9. Separate the discharge line from the condenser.
  10. Remove the discharge hose.
  11. Remove and discard the O-ring seals.
  1. Install new O-rings. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  2. Install the discharge hose.
  3. Connect the discharge hose to the compressor.
  4. Install the discharge hose bolt. Tighten: Tighten the bolt to 5.4 N.m (48 lb in).
  5. Connect the discharge hose to the compressor.
  6. Install the bolt to the discharge hose. Tighten: Tighten the bolt to 9.8 N.m (87 lb in).
  7. Install the engine splash shield. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) .
  8. Install the LH wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  9. Install the air deflector. Refer to «Air Deflector Replacement - Front»(ref-197566-S09922059352005101200000) .
  10. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  11. Using J 39400-A , leak test the fittings of the component. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197548-S05121562292005101200000) in Engine Controls - 3.6L.
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  4. Remove the LH wheel and tire assembly. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  5. Remove the engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-197566-S01756529562005101200000) .
  6. Remove the suction hose bolt at the compressor.
  7. Lower the vehicle.
  8. Remove the suction hose retaining screw from the clamp.
  9. Separate the liquid line from the A/C suction line bracket.
  10. Remove the suction hose quick connect fitting at the bulk head. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  11. Disconnect the suction hose from the evaporator core.
  12. Remove the suction hose from the vehicle.
  13. Remove and discard the O-ring seals.
  1. Install the new O-rings into the suction hose. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  2. Install the suction hose.
  3. Connect the suction hose to the evaporator core.
  4. Install the suction hose quick connect fitting. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  5. Position the liquid line into the bracket.
  6. Install the suction hose retaining screw into the bracket. Tighten: Tighten the screw to 1 N.m (9 lb in).
  7. Raise the vehicle.
  8. Connect the suction hose to the compressor.
  9. Install the retaining bolt to the compressor. Tighten: Tighten the bolt to 9.8 N.m (87 lb in).
  10. Install the engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-197566-S01756529562005101200000) .
  11. Install the LH wheel and tire assembly. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  12. Lower the vehicle.
  13. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197548-S05121562292005101200000) in Engine Controls - 3.6L (LY7).
  14. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  15. Using J 39400-A , leak test the fittings of the component. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197553-S28415702912005101200000) in Engine Control-4.6L.
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  4. Remove the LH wheel and tire assembly. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  5. Remove the engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-197566-S01756529562005101200000) .
  6. Remove the suction hose bolt at the compressor.
  7. Lower the vehicle.
  8. Remove the suction hose retaining screw from the clamp.
  9. Separate the liquid line from the A/C suction line bracket.
  10. Remove the suction hose quick connect fitting at the bulk head. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  11. Disconnect the suction hose from the evaporator core.
  12. Remove the suction hose from the vehicle.
  13. Remove and discard the O-ring seals.
  1. Install new O-rings onto the suction hose. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  2. Install the suction hose.
  3. Connect the suction hose to the evaporator core.
  4. Install the suction hose quick connect fitting. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  5. Position the liquid line into the bracket.
  6. Install the suction hose retaining screw into the clamp. Tighten: Tighten the screw to 1 N.m (9 lb in).
  7. Raise the vehicle.
  8. Connect the suction hose to the compressor.
  9. Install the retaining bolt to the compressor. Tighten: Tighten the bolt to 9.8 N.m (87 lb in).
  10. Install the engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-197566-S01756529562005101200000) .
  11. Install the LH wheel and tire assembly. Refer to «Tire and Wheel Removal and Installation»(ref-197568-S26287798292005101200000) .
  12. Lower the vehicle.
  13. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197553-S28415702912005101200000) in Engine Control-4.6L.
  14. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  15. Using J 39400-A , leak test the fittings of the component. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Remove the air cleaner from the vehicle. Refer to «Air Cleaner Assembly Replacement»(ref-197548-S05121562292005101200000) in Engine Controls - 3.6L (LY7).
  3. Disconnect the quick connect fitting at the condenser tube. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  4. Disconnect the liquid line from the strut tower retaining clip.
  5. Remove the wiper motor module assembly. Refer to «Wiper Motor Module Replacement»(ref-197570-S40722643032005101200000) .
  6. Disconnect the quick connect fitting at the evaporator core. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  7. Disconnect the liquid line from the evaporator core.
  8. Remove the liquid line from the vehicle.
  9. Remove and discard the O-ring seals.
  1. Install new O-rings to the liquid line. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  2. Install the liquid line in to the vehicle.
  3. Connect the liquid line to the evaporator core.
  4. Install the A/C quick connect fitting. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  5. Install the wiper motor module assembly. Refer to «Wiper Motor Module Replacement»(ref-197570-S40722643032005101200000) .
  6. Connect the liquid line to the strut tower retaining clip.
  7. Connect the liquid line to the condenser tube.
  8. Install the A/C quick connect fitting. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  9. Install the air cleaner from the vehicle. Refer to «Air Cleaner Assembly Replacement»(ref-197548-S05121562292005101200000) in Engine Controls - 3.6L.
  10. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  11. Using J 39400-A leak test the fittings of the component. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Remove the air cleaner from the vehicle. Refer to «Air Cleaner Assembly Replacement»(ref-197553-S28415702912005101200000) in Engine Control-4.6L.
  3. Disconnect the quick connect fitting at the condenser tube. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  4. Disconnect the liquid line from the strut tower retaining clip.
  5. Remove the wiper motor module assembly. Refer to «Wiper Motor Module Replacement»(ref-197570-S40722643032005101200000) .
  6. Disconnect the quick connect fitting at the evaporator core. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  7. Disconnect the liquid line from the evaporator core.
  8. Remove the liquid line from the vehicle.
  9. Remove and discard the O-ring seals.
  1. Install new O-rings to the liquid line. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  2. Install the liquid line in to the vehicle.
  3. Connect the liquid line to the evaporator core.
  4. Install the A/C quick connect fitting. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  5. Install the wiper motor module assembly. Refer to «Wiper Motor Module Replacement»(ref-197570-S40722643032005101200000) .
  6. Connect the liquid line to the strut tower retaining clip.
  7. Connect the liquid line to the condenser tube.
  8. Install the A/C quick connect fitting. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  9. Install the air cleaner from the vehicle. Refer to «Air Cleaner Assembly Replacement»(ref-197553-S28415702912005101200000) in Engine Control-4.6L.
  10. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  11. Using J 39400-A , leak test the fittings of the component. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Remove the electrical center cover.
  2. Remove the A/C compressor relay (1) from the electrical center.
  1. Install the A/C compressor relay (1) to the electrical center.
  2. Install the electrical center cover.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Remove the front air deflector. Refer to «Air Deflector Replacement - Front»(ref-197566-S09922059352005101200000) .
  3. Remove the desiccant bag plug (1).
  4. Remove the desiccant bag (1).
  1. Install the desiccant bag (1).
  2. Lubricate the O-rings on the desiccant bag plug. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  3. Install the desiccant bag plug (1). Tighten: Tighten the plug to 2.9 N.m (26 lb in).
  4. Install the front air deflector. Refer to «Air Deflector Replacement - Front»(ref-197566-S09922059352005101200000) .
  5. Lower the vehicle.
  6. Add the proper amount of oil. Refer to «Refrigerant System Capacities»(ref-197627-S12545243142005101200000) .
  7. Evacuate and recharge the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  8. Using J 39400-A , leak test the fittings of the component. See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Remove the instrument panel (I/P) retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-197555-S42454618682005101200000) .
  2. Remove the insulation (1) from the thermal expansion valve (TXV). Discard the used insulation.
  3. Remove the HVAC line clamp screw.
  4. Remove the HVAC line clamp.
  5. Remove the bolts (1) that secure the TXV to the evaporator.
  6. Remove the TXV line bracket.
  7. Remove the TXV from the evaporator core.
  8. Separate the TXV from the A/C lines by pulling straight out.
  9. Remove the TXV.
  1. Lubricate the O-rings. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  2. Install the A/C lines into the TXV.
  3. Carefully slide the TXV onto the evaporator core until seated.
  4. Install the TXV line bracket.
  5. Install the bolts (1) that secure the TXV to the evaporator. Tighten: Tighten the bolts to 3.5 N.m (31 lb in).
  6. Install the HVAC line clamp.
  7. Install the HVAC line clamp screw. Tighten: Tighten the screw to 1 N.m (8 lb in).
  8. Install new insulation (1) onto the lines and TXV.
  9. Install the I/P retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-197555-S42454618682005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197548-S05121562292005101200000) or to «Air Cleaner Assembly Replacement»(ref-197553-S28415702912005101200000) .
  3. Disconnect the electrical connector (1) from the A/C refrigerant pressure sensor (2).
  4. Remove the A/C refrigerant pressure sensor.
  1. Lubricate the O-ring with refrigerant oil. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  2. Install the A/C refrigerant pressure sensor (2). Tighten: Tighten the sensor to 9.8 N.m (87 lb in).
  3. Connect the electrical connector (1) to the A/C refrigerant pressure sensor.
  4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197548-S05121562292005101200000) or to «Air Cleaner Assembly Replacement»(ref-197553-S28415702912005101200000) .
  5. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  6. Leak test the fittings of the component using J 39400-A . See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Remove the power steering cooler mounting bolts. Refer to «Power Steering Cooler Replacement (LY7 W/O V92)»(ref-197600-S10910599352005101200000) or «Power Steering Cooler Replacement (LH2 or LY7 with V92)»(ref-197600-S14890821232005101200000) in Power Steering System.
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  4. Remove the front air deflector retainers.
  5. Remove the front air deflector.
  6. Remove the lower air baffle push pin retainers.
  7. Remove the condenser upper bracket bolts.
  8. Remove the condenser lower mounting bolts.
  9. Remove the discharge line bolt.
  10. Disconnect the discharge line from the condenser.
  11. Remove and discard the O-ring.
  12. Remove the condenser tube bolt.
  13. Disconnect the condenser tube from the condenser.
  14. Remove and discard the O-ring.
  15. Reposition the power steering cooler.
  16. Remove the condenser.
  1. If replacing the condenser, add the specified amount of PAG oil directly to the condenser. Refer to «Refrigerant System Capacities»(ref-197627-S12545243142005101200000) .
  2. Install the condenser.
  3. Reposition the power steering cooler into position.
  4. Install a new O-ring to the condenser tube. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  5. Connect the condenser tube to the condenser.
  6. Install the condenser tube bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  7. Install a new O-ring to the discharge line. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  8. Connect the discharge line to the condenser.
  9. Install the discharge line bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  10. Install the condenser lower mounting bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  11. Remove the condenser upper bracket bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  12. Install the lower air baffle push pin retainers.
  13. Install the front air deflector.
  14. Install the front air deflector retainers.
  15. Lower the vehicle.
  16. Install the power steering cooler mounting bolts. Refer to «Power Steering Cooler Replacement (LY7 W/O V92)»(ref-197600-S10910599352005101200000) or «Power Steering Cooler Replacement (LH2 or LY7 with V92)»(ref-197600-S14890821232005101200000) in Power Steering System.
  17. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  18. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  3. Remove the front air deflector retainers.
  4. Remove the front air deflector.
  5. Remove the lower air baffle push pin retainers.
  6. Remove the condenser upper bracket bolts.
  7. Remove the condenser lower mounting bolts.
  8. Remove the discharge line bolt.
  9. Disconnect the discharge line from the condenser.
  10. Remove and discard the O-ring.
  11. Remove the condenser tube bolt.
  12. Disconnect the condenser tube from the condenser.
  13. Remove and discard the O-ring.
  14. Remove the power steering cooler line to condenser retaining bolts.
  15. Remove the condenser.
  1. If replacing the condenser, add the specified amount of PAG oil directly to the condenser. Refer to «Refrigerant System Capacities»(ref-197627-S12545243142005101200000) .
  2. Install the condenser.
  3. Install the power steering cooler line to condenser retaining bolts. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  4. Install a new O-ring to the condenser tube. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  5. Connect the condenser tube to the condenser.
  6. Install the condenser tube bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  7. Install a new O-ring to the discharge line. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  8. Connect the discharge line to the condenser.
  9. Install the discharge line bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  10. Install the condenser lower mounting bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  11. Remove the condenser upper bracket bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  12. Install the lower air baffle push pin retainers.
  13. Install the front air deflector.
  14. Install the front air deflector retainers.
  15. Lower the vehicle.
  16. Install the power steering cooler mounting bolts. Refer to «Power Steering Cooler Replacement (LY7 W/O V92)»(ref-197600-S10910599352005101200000) or «Power Steering Cooler Replacement (LH2 or LY7 with V92)»(ref-197600-S14890821232005101200000) in Power Steering System.
  17. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  18. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  2. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  3. Disconnect the heater inlet hose from the heater core. Refer to «Heater Hose Replacement - Inlet (LY7)»(ref-197627-S34274558512005101200000) or «Heater Hose Replacement - Inlet (LH2)»(ref-197627-S29921844502005101200000) .
  4. Disconnect the heater outlet hose from the heater core. Refer to «Heater Hose Replacement - Outlet (LY7)»(ref-197627-S35047500202005101200000) or «Heater Hose Replacement - Outlet (LH2)»(ref-197627-S35921984332005101200000) .
  5. At the evaporator core, disconnect and remove the A/C quick connect fittings from the suction hose and the liquid line. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  6. Separate the suction hose and liquid line from the evaporator core.
  7. Remove and discard the O-rings.
  8. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-197555-S10899981542005101200000) .
  9. Remove the air inlet assembly.
  10. Disconnect the HVAC module electrical connector.
  11. Disconnect the HVAC module drain tube (2) from the floor.
  12. Remove the lower left HVAC module mounting nut (1).
  13. Remove the upper left HVAC module mounting nut (1).
  14. Remove the HVAC module from the vehicle.
  15. Remove the foam from the A/C lines.
  16. Remove the foam from around the heater pipes.
  1. Install the thick foam packing (1) on the heater core pipes.
  2. Install the thin foam packing (2) on the heater core pipes.
  3. Install the thick foam packing (1) on the A/C lines.
  4. Install the thin foam packing (2) on the A/C lines.
  5. Install the HVAC module into the vehicle.
  6. Install the upper left HVAC module mounting nut (1). Tighten: Tighten the nut to 9 N.m (80 lb in).
  7. Install the lower left HVAC module mounting nut (1). Tighten: Tighten the nut to 9 N.m (80 lb in).
  8. Connect the drain tube to the bottom of the HVAC module.
  9. Connect the drain tube (2) to the floor.
  10. Connect the HVAC electrical connector.
  11. Install the air inlet assembly.
  12. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-197555-S10899981542005101200000) .
  13. Install new O-rings to the suction hose and liquid line. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  14. Connect the suction hose and liquid line to the evaporator core.
  15. Install the A/C quick connect fittings to the suction hose and liquid line. Refer to «A/C Line/Tube Connector Removal/Replacement»(ref-197627-S33123802702005101200000) .
  16. Connect the heater inlet hose to the heater core. Refer to «Heater Hose Replacement - Inlet (LY7)»(ref-197627-S34274558512005101200000) or «Heater Hose Replacement - Inlet (LH2)»(ref-197627-S29921844502005101200000) .
  17. Connect the heater outlet hose to the heater core. Refer to «Heater Hose Replacement - Outlet (LY7)»(ref-197627-S35047500202005101200000) or «Heater Hose Replacement - Outlet (LH2)»(ref-197627-S35921984332005101200000) .
  18. Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  19. Evacuate and recharge the AC system. Refer to «Refrigerant Recovery and Recharging»(ref-197627-S11105497692005101200000) .
  20. Leak test the fittings of the component using J 39400-A . See «Special Tools»(ref-197627-S36369102382005101200000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-197627-S14955301952005101200000) .
  2. Remove and discard the insulation (1) from the thermal expansion valve (TXV).
  3. Remove the HVAC line clamp screw.
  4. Remove the HVAC line clamp.
  5. Remove the TXV to evaporator bolts (1).
  6. Remove the TXV line bracket.
  7. Remove the TXV from the evaporator core.
  8. Separate the TXV from the A/C lines by pulling straight out.
  9. Remove and discard all of the O-rings.
  10. Disconnect the thermistor electrical connector from the HVAC module retainer.
  11. Disconnect the LH and the auxiliary temperature actuator electrical connectors. Reposition the harness.
  12. Release the retainers and remove the front duct on the HVAC module
  13. Remove the screws that hold the case together.
  14. Separate the HVAC module.
  15. Remove the evaporator core.
  1. Add refrigerant oil. Refer to «Refrigerant System Capacities»(ref-197627-S12545243142005101200000) .
  2. Install new evaporator core seals to the evaporator.
  3. Install the evaporator core.
  4. Slide the HVAC module case halves together.
  5. Install the screws that hold the case together. Tighten: Tighten the screws to 1 N.m (8 lb in).
  6. Install the front duct on the HVAC module. Ensure that the retainers are properly engaged.
  7. Reposition the wire harness and connect the LH and the auxiliary temperature actuator electrical connectors.
  8. Connect the thermistor electrical connector to the HVAC module retainer.
  9. Install new O-rings to the evaporator core and the TXV lines. Refer to «O-Ring Replacement»(ref-197627-S18130523122005101200000) .
  10. Install the A/C lines into the TXV.
  11. Carefully slide the TXV onto the evaporator core until seated.
  12. Install the TXV line bracket.
  13. Install the TXV to evaporator bolts (1). Tighten: Tighten the bolts to 3.5 N.m (31 lb in).
  14. Install the HVAC line clamp.
  15. Install the HVAC line clamp screw. Tighten: Tighten the screw to 1 N.m (8 lb in).
  16. Install the insulation (1) onto the lines and the TXV.
  17. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-197627-S14955301952005101200000) .
  1. Remove the center console. Refer to «Console Replacement - Front Floor»(ref-197555-S08969593532005101200000) in Instrument Panel, Gages, and Console.
  2. Remove the rubber adhesive patch (1) from around the drain tube (2).
  3. Open the flap in the tunnel insulator and unsnap drain fitting from the tunnel sheet metal.
  4. Remove the HVAC module drain tube from the HVAC module.
  1. Install the HVAC module drain tube to the HVAC module.
  2. Ensure that the drain tube is fully seated to the HVAC module.
  3. Snap drain fitting into the tunnel sheet metal.
  4. Close the flap on the tunnel insulator.
  5. Install the rubber adhesive patch (1) around the drain tube (2).
  6. Install the center console. Refer to «Console Replacement - Front Floor»(ref-197555-S08969593532005101200000) in Instrument Panel, Gages, and Console.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) in Engine Cooling.
  2. Remove the battery tray. Refer to «Battery Tray Replacement»(ref-197559-S36028649372005101200000) in Engine Electrical.
  3. Remove the cowl panel retaining bolts.
  4. Remove the cowl panel.
  5. Using J 38185 slide the clamp away from the base of the heater inlet hose.
  6. Remove the inlet heater hose from the heater core.
  7. Using J 38185 slide the clamp away from the base of the heater inlet hose.
  8. Remove the clamp and hose from the engine cooling thermostat assembly.
  1. Install the inlet heater hose to the engine cooling thermostat assembly.
  2. Using J 38185 slide the clamp back into the original position on the hose.
  3. Install the inlet heater hose to the heater core.
  4. Using J 38185 slide the clamp back into the original position on the hose.
  5. Install the cowl panel.
  6. Install the cowl panel retaining bolts. Tighten: Tighten the bolts to 6 N.m (13 lb ft).
  7. Install the battery tray. Refer to «Battery Tray Replacement»(ref-197559-S36028649372005101200000) in Engine Electrical.
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Lower the vehicle.
  3. Remove the injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-197575-S37763020362005101200000) .
  4. Using J 38185 , disengage the hose clamp and disconnect the heater inlet hose (2) from the thermostat housing.
  5. Using J 38185 , disengage the hose clamp and disconnect the heater inlet hose (2) from the heater pipe assembly.
  6. Remove the heater inlet hose (2).
  1. Install the heater inlet hose (2).
  2. Using J 38185 , disengage the hose clamp and connect the heater inlet hose (2) to the heater pipe assembly.
  3. Using J 38185 , disengage the hose clamp and connect the heater inlet hose (2) to the thermostat housing.
  4. Install the injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-197575-S37763020362005101200000) .
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Lower the vehicle.
  3. Remove the injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-197575-S37763020362005101200000) .
  4. Using J 38185 , disengage the hose clamp and disconnect the heater outlet hose (1) from the heater pipe assembly.
  5. Using J 38185 , disengage the hose clamp and disconnect the heater inlet hose (2) from the heater pipe assembly.
  6. Using J 38185 , disengage the hose clamp and disconnect the surge tank outlet hose from the heater pipe assembly.
  7. Using J 38185 , disengage the hose clamps and disconnect the heater pipe assembly from the heater core.
  8. Remove the battery tray. Refer to «Battery Tray Replacement»(ref-197559-S36028649372005101200000) .
  9. Remove the heater pipe assembly retaining nuts.
  10. Reposition the engine wiring harness aside.
  11. Remove the heater pipe assembly.
  1. Install the heater pipe assembly.
  2. Reposition the engine wiring harness into place.
  3. Install the heater pipe assembly retaining nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in)
  4. Install the battery tray. Refer to «Battery Tray Replacement»(ref-197559-S36028649372005101200000) .
  5. Using J 38185 , disengage the hose clamps and connect the heater pipe assembly to the heater core.
  6. Using J 38185 , disengage the hose clamp and connect the surge tank outlet hose to the heater pipe assembly.
  7. Using J 38185 , disengage the hose clamp and connect the heater inlet hose (2) to the heater pipe assembly.
  8. Using J 38185 , disengage the hose clamp and connect the heater outlet hose (1) to the heater pipe assembly.
  9. Install the injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-197575-S37763020362005101200000) .
  10. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) in Engine Cooling.
  2. Remove the battery tray. Refer to «Battery Tray Replacement»(ref-197559-S36028649372005101200000) in Engine Electrical.
  3. Remove the cowl panel retaining bolts.
  4. Remove the cowl panel.
  5. Using J 38185 slide the hose clamp away from the base of the heater hose.
  6. Remove the outlet heater hose from the engine cooling thermostat assembly.
  7. Using J 38185 , slide the hose clamp away from the base of the heater hose.
  8. Remove the heater outlet hose from the heater core.
  9. Remove the heater outlet hose.
  1. Position the outlet heater hose assembly into the vehicle.
  2. Install the outlet hose to the heater core.
  3. Using J 38185 slide the hose clamp back into the original position on the hose.
  4. Install the outlet hose to the engine cooling thermostat assembly.
  5. Using J 38185 slide the hose clamp back into the original position on the hose.
  6. Install the cowl panel.
  7. Install the cowl panel retaining bolts. Tighten: Tighten the bolts to 6 N.m (13 lb ft).
  8. Install the battery tray. Refer to «Battery Tray Replacement»(ref-197559-S36028649372005101200000) in Engine Electrical.
  9. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Lower the vehicle.
  3. Remove the injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-197575-S37763020362005101200000) .
  4. Using J 38185 , disengage the hose clamp and disconnect the heater outlet hose (1) from the radiator hose outlet housing.
  5. Using J 38185 , disengage the hose clamp and disconnect the heater outlet hose (1) from the heater pipe assembly.
  6. Remove the heater outlet hose (1).
  1. Install the heater outlet hose (1).
  2. Using J 38185 , disengage the hose clamp and connect the heater outlet hose (1) to the heater pipe assembly.
  3. Using J 38185 , disengage the hose clamp and connect the heater outlet hose (1) to the radiator hose outlet housing.
  4. Install the injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-197575-S37763020362005101200000) .
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) in Body Front End.
  2. With two hands release the tabs on each side of the access cover.
  3. Lift up the filter access cover (1).
  4. Remove the filter (1) from the filter housing.
  5. Gently pry out on the filter housing to separate the housing from the sheet metal.
  6. Remove the passenger air filter housing (1).
  1. Install the passenger air filter housing (1).
  2. Press the passenger air filter housing until all clips engage into the sheet metal.
  3. Ensure that there is a good seal between the passenger air filter housing and the sheet metal.
  4. Install the filter (1) in to the filter housing.
  5. Install the filter access cover (1).
  6. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) in Body Front End.
  1. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) in Body Front End.
  2. With two hands release the tabs on each side of the access cover.
  3. Lift up the filter access cover (1).
  4. Remove the filter (1) from the filter housing.
  1. Install the filter (1) in to the filter housing.
  2. Install the filter access cover (1).
  3. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) in Body Front End.
  1. Remove the instrument panel (I/P) compartment. Refer to «Compartment Replacement - Instrument Panel (I/P)»(ref-197555-S41910413392005101200000) Instrument Panel, Gages, and Console.
  2. Remove the closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-197555-S42331658092005101200000) or «Closeout/Insulator Panel Replacement - Left»(ref-197555-S24459859312005101200000) in Instrument Panel, Gages, and Console.
  3. Remove the upper air inlet assembly bolts (1).
  4. Remove the lower right air inlet assembly bolt (1).
  5. Slide the assembly to the right and then lower.
  6. Disconnect the air inlet assembly electrical connector (1).
  7. Rotate the air inlet assembly (1) and remove.
  1. Connect the air inlet assembly electrical connector (1).
  2. Install the air inlet assembly (1) to the locator pin.
  3. Install the upper air inlet assembly bolts (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
  4. Install the lower right air inlet assembly bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
  5. Install the I/P compartment. Refer to «Compartment Replacement - Instrument Panel (I/P)»(ref-197555-S41910413392005101200000) in Instrument Panel, Gages, and Console.
  6. Install the closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-197555-S42331658092005101200000) or «Closeout/Insulator Panel Replacement - Left»(ref-197555-S24459859312005101200000) in Instrument Panel, Gages, and Console.
  1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-197574-S25852276312005101200000) .
  2. Remove the windshield wiper arms. Refer to «Wiper Arm Replacement»(ref-197570-S06304090922005101200000) .
  3. Remove the air inlet grille panels (1,3). Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) .
  4. Disconnect the electrical connector (4) from the windshield wiper motor.
  5. Remove the wiper motor module (6). Refer to «Wiper Motor Module Replacement»(ref-197570-S40722643032005101200000) .
  6. Remove the fasteners securing the panel assembly to the front of the dash.
  7. Remove the panel assembly from the vehicle.
  1. Install the panel assembly for the front air inlet housing to the vehicle.
  2. Install the fasteners securing the panel assembly to the front of the dash. Tighten: Tighten the bolt to 6 N.m (53 lb in).
  3. Install the wiper motor module (6). Refer to «Wiper Motor Module Replacement»(ref-197570-S40722643032005101200000) .
  4. Install the electrical connector (4) to the windshield wiper motor.
  5. Install the air inlet grille panels (1,3). Refer to «Air Inlet Grille Panel Replacement»(ref-197566-S29625862982005101200000) .
  6. Install the windshield wiper arms. Refer to «Wiper Arm Replacement»(ref-197570-S06304090922005101200000) .
  7. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-197574-S25852276312005101200000) .
  1. Remove the right closeout insulator panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-197555-S42331658092005101200000) in Instrument Panel, Gages, and Console.
  2. Remove the instrument panel (I/P) compartment. Refer to «Compartment Replacement - Instrument Panel (I/P)»(ref-197555-S41910413392005101200000) in Instrument Panel, Gages, and Console.
  3. Disconnect the blower motor electrical connector.
  4. Disconnect the blower motor processor electrical connector.
  5. Remove the screws (1) that retain the blower motor.
  6. Remove the air inlet housing bolts to gain clearance for the blower motor.
  7. Remove the blower motor.
  1. Install the blower motor.
  2. Install the blower motor screws (1). Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  3. Install the air inlet housing bolts. Tighten: Tighten the screws to 6 N.m (53 lb in).
  4. Connect the blower motor processor electrical connector.
  5. Connect the blower motor electrical connector.
  6. Install the I/P compartment. Refer to «Compartment Replacement - Instrument Panel (I/P)»(ref-197555-S41910413392005101200000) in Instrument Panel, Gages, and Console.
  7. Install the right closeout insulator panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-197555-S42331658092005101200000) in Instrument Panel, Gages, and Console.
  1. Remove the instrument panel (I/P) center trim. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(ref-197555-S08876510802005101200000) in Instrument Panel, Gages, and Console.
  2. Release the tabs securing the outlet air deflector to the I/P center trim.
  1. Locate the tabs securing the outlet air deflector to the I/P center trim.
  2. Install the I/P center trim. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(ref-197555-S08876510802005101200000) in Instrument Panel, Gages, and Console.
  1. Use a blunt trim tool in order to release the tabs securing the outlet air deflector to the instrument panel (I/P).
  2. Pull out on the deflector to remove from the I/P.
  1. Locate the vent to the I/P.
  2. Push the outlet vent securing the outlet air deflector to the I/P.
  1. Remove the instrument panel (I/P) retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-197555-S42454618682005101200000) in Instrument Panel, Gages, and Console.
  2. Remove the foam dash pad (1).
  3. Disconnect the wiring harness from the air duct.
  4. Remove the screws (1) that retain the air duct.
  5. Remove the left air duct (2), by unsnapping the air duct from the HVAC module.
  1. Install the left air duct (2), by pressing down until you hear the tabs engage on the HVAC module.
  2. Install the air outlet duct screws (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  3. Connect the wiring harness to the air duct.
  4. Install the foam dash pad (1).
  5. Install the I/P retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-197555-S42454618682005101200000) in Instrument Panel, Gages, and Console.
  1. Remove the instrument panel (I/P) retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-197555-S42454618682005101200000) in Instrument Panel, Gages, and Console.
  2. Remove the foam dash pad (1).
  3. Disconnect the wiring harness from the air duct (1).
  4. Remove the screws (1) that retain the air duct (2).
  5. Remove the right air duct (2), by releasing the tabs from the module.
  1. Install the right air duct (2), by pressing down until you hear the tabs engage on the HVAC module.
  2. Install the right air duct screws (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  3. Connect the wiring harness to the air duct (1).
  4. Install the foam dash pad (1).
  5. Install the I/P retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-197555-S42454618682005101200000) in Instrument Panel, Gages, and Console.

Scheme 21

Scheme 21: Outlet Replacement - Auxiliary Air - Floor Console
Scheme 21: Outlet Replacement - Auxiliary Air - Floor Console
CalloutComponent Name
NOTE: Refer to Fastener Notice in Cautions and Notices. Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Remove the front seats. Refer to Seat Replacement - Bucket .
1Console, Front Floor Refer to Console Replacement - Front Floor .
2Screw, Auxiliary Air Outlet Duct Tighten: 2 N.m (17 lb in)
3Duct, Passenger Side Auxiliary Floor Air Tip: Reposition the carpet to access the rear floor air ducts.
4Driver Side Auxiliary Floor Air Duct Tip: Using blunt trim tool release the tabs to separate the Auxiliary Floor Ducts.
5Retainer Push Pin (Qty: 2) Tip: There are two push in retainers per Floor - Rear Air Outlet Duct.
6Outlet, Floor Rear Air
NOTE
Refer to Fastener Notice in Cautions and Notices.

Outlet Replacement - Auxiliary Air - Floor Console

  1. Remove the instrument panel (I/P) retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-197555-S42454618682005101200000) in Instrument Panel, Gages, and Console.
  2. Remove the pushpins.
  3. Press in on the tab to release the defroster duct (1) from the HVAC module.
  4. Remove the defroster duct (1).
  1. Install the defroster duct (1).
  2. Press down on the defroster duct (1) until you hear the tabs engage.
  3. Install the pushpins to the mag beam.
  4. Install the I/P retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-197555-S42454618682005101200000) in Instrument Panel, Gages, and Console.
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-197627-S14955301952005101200000) .
  2. Remove the heater hose bracket screw.
  3. Remove the heater hose bracket (1).
  4. Slide the heater core out of the HVAC module.
  1. Slide the heater core into the HVAC module.
  2. Install the heater hose bracket (1).
  3. Install the heater hose bracket screw. Tighten: Tighten the screws to 1 N.m (9 lb in)
  4. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-197627-S14955301952005101200000) .

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