Heating, Ventilation, and Air Conditioning Chevrolet Corvette C6

Fastener Tightening Specifications

Refrigerant System Capacities

Refrigerant System Capacities

Begin the system diagnosis with Diagnostic System Check - Vehicle . The Diagnostic System Check - Vehicle will provide the following information

1. The identification of the control modules which are not communicating.
2. The identification of any stored diagnostic trouble codes (DTCs) and their status.

The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis.

Special Tools

1. J 39400-A Halogen Leak Detector
2. J 41447 R-134A A/C Tracer Dye-Box of 24. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 42220 Universal 12V Leak Detection Lamp
4. J 43872 Fluorescent Dye Cleaner. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 46297 A/C Dye Injector Kit. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. J 46297-12 Replacement Dye Cartridges. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Refrigerant Leak Testing

Note. General Motors vehicles are now manufactured with fluorescent dye installed directly into the air conditioning (A/C) system.

The fluorescent dye mixes and flows with the polyalkylene glycol (PAG) oil throughout the refrigerant system.

Verifying some passive leaks may require using the J 39400-A , even though the A/C system contains fluorescent dye.

The only time that adding additional fluorescent dye is required is after flushing the A/C system.

Fluorescent Leak Detector

Fluorescent dye will assist in locating any leaks in the A/C system.

1. Condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.
2. Leaks in the A/C system will be indicated in a light green or yellow color when using the leak detection lamp. Use the leak detection lamp in the following areas: All fittings or connections that use seal washers or O-rings All of the A/C components The A/C compressor shaft seal The A/C hoses and pressure switches The HVAC module drain tube, if the evaporator core is suspected of leaking The service port sealing caps The sealing cap is the primary seal for the service ports.
3. Follow the instructions supplied with the J 42220 .
4. To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Use a rag and the approved J 43872 . See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Fluorescent Dye Injection

1. Not all of the fluorescent dyes are compatible with PAG oil. Some types of dye decrease the oil viscosity or may chemically react with the oil.
2. R-134A leak detection dye requires time to work. Depending upon the leak rate, a leak may not become visible for between 15 minutes and 7 days.
3. To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner J 43872 . See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Halogen Leak Detector

Ensure that the vehicle has at least 0.45 kg (1 lb) of refrigerant in the A/C refrigeration system in order to perform a leak test. Refer to Refrigerant Recovery and Recharging for recharging the A/C system.

Note. Halogen leak detectors are sensitive to the following items: Windshield washing solutions Many solvents and cleaners Some adhesives used in the vehicle

Clean and dry all surfaces in order to prevent a false warning. Liquids will damage the detector.

Note. Follow a continuous path in order to ensure that you will not miss any possible leaks. Test all areas of the system for leaks.

Follow the instructions supplied with the J 39400-A .

Test Description

This test measures the operating efficiency of the A/C system under the following conditions

1. The current ambient air temperature (AAT)
2. The current relative humidity
3. The high side pressure of the A/C system
4. The low side pressure of the A/C system
5. The temperature of the air being discharged into the passenger compartment

The numbers below refer to the step numbers on the diagnostic table.

1. 1: This step determines if the A/C system has at least the minimum refrigerant charge required to operate the system without damage.
2. 2: This step measures the performance of the A/C system.
3. 3: This step is to allow for vehicle variations as well as high ambient temperatures.

Scheme 1

A/C Performance Table

Air Conditioning (A/C) Diagnostics - Pressure Zone A

Air Conditioning (A/C) Diagnostics - Pressure Zone B

Air Conditioning (A/C) Diagnostics - Pressure Zone C

Air Conditioning (A/C) Diagnostics - Pressure Zone D

Heating Performance Diagnostic

Defrosting Insufficient

Noise Diagnosis - Blower Motor

Air Conditioning Compressor Oil Diagnosis

Note. To avoid repeat compressor failure, always inspect the condition of the refrigerant oil and take the appropriate corrective action before installing the replacement compressor.

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - HVAC Module

Odor Diagnosis

Eliminating Air Conditioning (A/C) Odor

Odors may be emitted from the air conditioning system primarily at start up in hot, humid climates. The following conditions may cause the odor

1. Debris is present in the HVAC module
2. Microbial growth on the evaporator core

When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. To remove odors of this type, the microbial growth must be eliminated. Perform the following procedure

Deodorize the evaporator core using Deodorizing Aerosol Kit.

Perform the following steps in order to deodorize the A/C system

1. Ensure that the plenum which draws outside air into the HVAC module is clear of debris.
2. Disable the air conditioning (A/C) compressor clutch operation by disconnecting the clutch coil electrical connector.
3. Dry the evaporator core by performing the following steps: Start the engine. Select the warmest temperature setting. Select the recirculation mode. Run the blower motor on high for 10 minutes.
4. Locate an area in the air conditioning duct between the blower motor and the evaporator core downstream of the blower motor.
5. Drill a 3.175 mm (0.125 in) hole where the hole will not interfere with or damage the following components: The blower motor The evaporator core Any other operating part the of system
6. Wear safety goggles and latex gloves in order to perform the following actions: Select the maximum blower speed. Insert the deodorizer extension tube into the hole to the mark on the extension tube. Use short spray bursts and vary the direction of spray for a 2-3 minute period of time.
7. Shut the engine OFF. Allow the vehicle to sit for 3-5 minutes.
8. Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.
9. Start the engine.
10. Operate the blower motor on high for 15-20 minutes to dry.
11. Reconnect the A/C compressor clutch coil electrical connector.
12. Verify proper A/C clutch operation.

1. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 45037 A/C Oil Injector. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

The J 43600 is a complete air conditioning service center for R-134a. See Special Tools . The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant.

The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system.

The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.

Refer to the J 43600 ACR 2000 manual for operation and setup instruction. See Special Tools . Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount.

A/C Refrigerant System Oil Charge Replenishing

If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . See Special Tools . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities .

1. J 41447: R-134a-Leak Detection Dye
2. J 42220: Universal 12V Leak Detection Lamp
3. J 43600: ACR 2000 Air Conditioning Service Center
4. J 45268: A/C Flush Adapter Kit

Note. Flushing with the ACR 2000 is not intended to remove metal from the A/C system.

Flushing is intended to remove the following

1. Contaminated polyalkylene glycol (PAG) oil
2. Desiccant, following a desiccant bag failure
3. Overcharge of PAG oil
4. Refrigerant contamination

Forward Flushing Setup

1. Install both J 45268-9 (2) onto the J 45268-10 (3).
2. Install the J 45268-7 (4) onto the suction side of the J 45268-10 (3).
3. Install the J 45268-8 (1) onto the discharge side of the J 45268-10 (3).

Reverse Flushing Setup

1. Install both J 45268-9 (2) onto the J 45268-10 (3).
2. Install the J 45268-8 (1) onto the suction side of the J 45268-10 (3).
3. Install the J 45268-7 (4) onto the discharge side of the J 45268-10 (3).

Scheme 2

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the thermal expansion valve (TXV). Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the stud onto the J 45268-115.
4. Install new sealing washers onto the evaporator core. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install J 45268-115 in place of the TXV.
6. Install TXV mounting bolts and tighten to 7 N.m (62 lb in).
7. Install new washers onto the rear evaporator line assembly. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Connect the rear evaporator line assembly to the J 45268-115.
9. Install the TXV block fitting nut and tighten to 20 N.m (15 lb ft).
10. Remove the A/C compressor. Refer to «Air Conditioning Compressor Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Remove the A/C refrigerant filter. Refer to «Air Conditioning (AC) Refrigerant Filter Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Service the filter with AC Delco P/N GF 470, before each flush.
13. Install the J 45268-10 to the compressor hose assembly.
14. Connect the J 45268-1 flush filter to the J 45268-7 flush adapter.
15. Connect the blue hose from the J 43600 to J 45268-1 flush filter adapter. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
16. Connect the red hose from the J 43600 to J 45268-8 flush adapter. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
17. Flush the A/C system. Follow the instructions supplied with the J 43600 . See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
18. Disconnect the red hose from the J 43600 to J 45268-8 flush adapter. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
19. Disconnect the blue hose from the J 43600 to J 45268-1 flush filter adapter. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
20. Disconnect the J 45268-1 flush filter from the J 45268-10 flush adapter.
21. Remove the J 45268-10 from the compressor hose assembly.
22. If you will reinstall the removed A/C compressor, perform the following procedure: Remove the A/C compressor drain plug. Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor. Add the total system capacity of PAG oil to the crankcase of the A/C compressor. Refer to «Refrigerant System Capacities»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) . NOTE: Flushing will remove the fluorescent leak detection dye from the A/C system. Add one bottle of J 41447 directly into the A/C compressor. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Install the A/C compressor drain plug and tighten to 15 N.m (11 lb ft).
23. Install the A/C compressor. Refer to «Air Conditioning Compressor Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
24. Install the A/C refrigerant filter. Refer to «Air Conditioning (AC) Refrigerant Filter Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
25. Remove the TXV block fitting nut.
26. Disconnect the rear evaporator line assembly from the J45268-115.
27. Remove the TXV bolts retaining the J 45268-115.
28. Remove the J 45268-115.
29. Inspect the TXV for debris. Clean or replace as needed.
30. Install the TXV. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
31. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
32. Leak test the fittings using J 42220 .

Draining Procedure

1. Remove the compressor crankcase oil drain bolt and drain the refrigerant oil from the crankcase and rear head ports into a clean, graduated container.
2. Rotate the compressor shaft to assist in draining the compressor.
3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
4. Inspect oil drained from removed compressor. Refer to «Air Conditioning Compressor Oil Diagnosis»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__air-conditioning-compressor-oil-diagnosis) .
5. Properly discard the used refrigerant oil.
6. Clean the graduated cylinder.
7. Remove the compressor crankcase oil drain bolt and drain the refrigerant oil from the crankcase and rear head ports into a clean, graduated container.
8. Rotate the compressor shaft to assist in draining the compressor.

Balancing Procedure

1. Refer to the amount of refrigerant oil recorded during the compressor removal.
2. If the amount of oil recorded from the removed compressor is less than or equal to 75 ml (2.5 fl. oz.), add 75 ml of the new PAG oil back into the new compressor through the compressor oil drain bolt hole.
3. Install the compressor oil drain bolt and tighten to 15 N.m (11 lb ft).
4. Rotate the clutch driver three times to lubricate the internal compressor components.
5. If necessary, refer to «Refrigerant System Capacities»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .

J 39400-A: Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant from the A/C System. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the A/C drive belt. Refer to «Air Conditioning Compressor Belt Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
3. Remove the A/C compressor hose assembly from the A/C compressor. Refer to «Air Conditioning Compressor Hose Replacement (LS3, LS7)»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Lower the front suspension crossmember. Refer to «Front Suspension Crossmember Replacement (With Z06 or ZR1)»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Suspension Crossmember Replacement (Without Z06)»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
5. Disconnect the A/C compressor electrical connector.
6. Remove the A/C compressor mounting bolts (1, 2, 4).
7. Remove the A/C compressor mounting nut (3).
8. Remove the A/C compressor from the vehicle.
9. If replacing the A/C compressor, oil balance the compressor. Refer to «Air Conditioning Compressor Oil Balancing»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Installation Procedure

1. Install the A/C compressor to the vehicle.
2. Position the A/C compressor onto the A/C compressor bracket and install the A/C compressor mounting bolts (1, 2, 4).
3. Install the A/C compressor mounting nut (3).
4. Tighten the A/C compressor mounting bolts and nut in sequence to 50 N.m (37 lb ft).
5. Connect the A/C compressor electrical connector.
6. Raise and install the front suspension crossmember. Refer to «Front Suspension Crossmember Replacement (With Z06 or ZR1)»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Suspension Crossmember Replacement (Without Z06)»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
7. Install the compressor hose assembly to the A/C compressor. Refer to «Air Conditioning Compressor Hose Replacement (LS3, LS7)»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Install the A/C drive belt. Refer to «Air Conditioning Compressor Belt Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
9. Evacuate and recharge the A/C System. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
10. Leak test the fittings of the A/C components using J 39400-A: Halogen Leak Detector.

J 37872 Universal Spanner Wrench. See Special Tools .

1. Remove the air conditioning drive belt. Refer to «Air Conditioning Compressor Belt Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
2. Remove the electrical connector from the A/C compressor coil assembly.
3. Using J 37872 , remove and discard the air conditioning clutch screw (7). See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Remove the clutch driver (6) from the splined shaft.
5. Remove and discard the pulley and bearing assembly retainer (4).
6. Remove the pulley and bearing assembly (3) from the A/C compressor.
7. Remove and discard the coil assembly retainer (2).
8. Remove the coil assembly (1) from the A/C compressor.
9. Carefully clean the splined shaft and the retainer grooves of any foreign debris.
10. Carefully clean the shaft threads of adhesive using a M6 x 1.0 tap. Carefully blow out debris with compressed air.

1. Install the coil assembly (1) to the A/C compressor.
2. Install a new coil assembly retainer (2).
3. Install the pulley and bearing assembly (3) to the A/C compressor.
4. Install a new pulley and bearing assembly retainer (4).
5. Install the clutch driver (6) to the splined shaft.
6. Measure the air gap between the clutch driver (6) and pulley (3). The air gap should be between 0.3-0.6 mm (0.011-0.024 in).
7. Ensure that the clutch driver (6) does not drag against the pulley (3) when the pulley is rotated.
8. Using J 37872 , install a new air conditioning clutch screw (7). See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten: Tighten the screw to 10 N.m (89 lb in).
9. Connect the electrical connector to the A/C compressor coil assembly.
10. Install the air conditioning drive belt. Refer to «Air Conditioning Compressor Belt Replacement (w/o LS9)»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the RH tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/corvette/c6-2004-2014/remont/wheel-tire-system/#tires-and-wheels) .
3. Remove the high pressure relief valve.
4. Cap or tape the A/C compressor high pressure relief valve port.

1. Remove the cap or tape from the A/C compressor high pressure relief valve port.
2. Install the high pressure relief valve and tighten to 8 N.m (70 lb in).
3. Remove the RH tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/corvette/c6-2004-2014/remont/wheel-tire-system/#tires-and-wheels) .
4. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

1. Remove the seal washer from the A/C refrigerant component.
2. Inspect the seal washer for any signs of damage.
3. Inspect the A/C refrigerant components for damage or burrs. Repair or replace as necessary.
4. Discard the sealing washer.

1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
2. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
3. Carefully install the new seal washer onto the A/C refrigerant component.
4. The washer must completely bottom against the surface of the fitting.
5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.

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.
4. Inspect the A/C refrigerant components for damage or burrs. Repair or replace as necessary.
5. Discard the O-ring seal.

1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
2. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.
3. Lightly coat the new O-ring seal and thread fitting with mineral base 525 viscosity refrigerant oil.
4. Carefully slide the new O-ring seal onto the A/C refrigerant component.
5. The O-ring seal must be fully seated.
6. Assemble the A/C components. Refer to the appropriate repair procedure.

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Locate the A/C coupling assembly locking tab access slots (1).
3. Carefully insert a small flat-bladed screwdriver into the first locking tab access slot and gently lift the locking tab to release the lock.
4. Carefully insert a small flat-bladed screwdriver into the second locking tab access slot and gently lift the locking tab to release the lock.
5. Open and remove the A/C coupling assembly from the A/C refrigerant component.

1. Install the A/C coupling assembly to the A/C refrigerant component.
2. Close the A/C coupling assembly.
3. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Leak test the fittings of the component using J 39400-A .

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the radiator support. Refer to «Radiator Support Replacement»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the A/C compressor hose assembly bolt from the A/C condenser fitting.
4. Disconnect the A/C compressor hose assembly from the A/C condenser fitting.
5. Remove and discard the sealing washer.
6. Cap or tape off the A/C condenser fitting.
7. Disconnect and remove the A/C tube connector from the evaporator outlet tube and A/C compressor hose assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Disconnect the evaporator outlet tube from the A/C compressor hose assembly.
9. Cap or tape off the evaporator outlet tube.
10. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
11. Remove the right front tire and wheel assembly from the vehicle. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/corvette/c6-2004-2014/remont/wheel-tire-system/#tires-and-wheels) +.
12. For the 7.0L only, remove the compressor mounting bolts and nuts and lower the compressor. Refer to «Air Conditioning Compressor Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
13. Remove the A/C compressor hose assembly to A/C compressor retaining bolt.
14. Disconnect the A/C compressor hose assembly from the A/C compressor.
15. Remove and discard the sealing washers.
16. Cap or tape off the A/C compressor.
17. Remove the A/C compressor hose assembly from the vehicle.

1. Install the A/C compressor hose assembly to the vehicle.
2. Remove cap or tape from the A/C compressor.
3. Install new sealing washers onto the compressor hose assembly. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Connect the A/C compressor hose assembly to the A/C compressor.
5. Install the A/C compressor hose assembly to A/C compressor retaining bolt and tighten to 20 N.m (15 lb ft).
6. For the 7.0L only, reposition the compressor and install the bolts and nuts. Refer to «Air Conditioning Compressor Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Install the right front tire and wheel assembly to the vehicle. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/corvette/c6-2004-2014/remont/wheel-tire-system/#tires-and-wheels) .
8. Lower the vehicle.
9. Remove cap or tape from the evaporator outlet tube.
10. Install a new O-rings onto the evaporator outlet tube. Refer to «O-Ring Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Connect the evaporator outlet tube to the A/C compressor hose assembly.
12. Install the A/C tube connector to the evaporator outlet tube and A/C compressor hose assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
13. Remove cap or tape from the A/C condenser fitting.
14. Install a new sealing washer onto the compressor hose assembly. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
15. Connect the A/C compressor hose assembly to the A/C condenser fitting.
16. Install the A/C compressor hose assembly bolt to the A/C condenser fitting and tighten to 16 N.m (12 lb ft).
17. Install the radiator support. Refer to «Radiator Support Replacement»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
18. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
19. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the battery. Refer to «Battery Replacement (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Replacement (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
3. Disconnect and remove the A/C tube connector (1) at the evaporator rear line assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Disconnect the front evaporator inlet line from the body retaining clip.
5. Disconnect the refrigerant pressure sensor electrical connector.
6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
7. Remove the front evaporator inlet line to A/C condenser lower bolt.
8. Disconnect the front evaporator line inlet from the A/C condenser.
9. Remove and discard the sealing washer.
10. Cap or tape off the A/C condenser.
11. Lower the vehicle.
12. Disconnect the front evaporator inlet line from the evaporator rear line assembly.
13. Remove and discard the O-rings.
14. Cap or tape the evaporator rear line assembly.
15. Disconnect the surge tank outlet hose and the inlet heater hose from the underhood junction box retainer clip.
16. Remove the front evaporator inlet line from the vehicle.

1. Install the front evaporator inlet line to the vehicle.
2. Connect the surge tank outlet hose and the inlet heater hose to the underhood junction box retainer clip (1).
3. Remove cap or tape from the evaporator rear line assembly.
4. Install new O-rings to the rear evaporator line assembly. Refer to «O-Ring Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Connect the front evaporator inlet line to the evaporator rear line assembly.
6. Raise the vehicle.
7. Remove cap or tape from the A/C condenser.
8. Install a new sealing washer to the front evaporator inlet line. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Connect the front evaporator inlet line to the A/C condenser.
10. Install the front evaporator inlet line to A/C condenser lower bolt and tighten to 16 N.m (12 lb ft).
11. Lower the vehicle.
12. Connect the front evaporator inlet line to the body retaining clip (1).
13. Connect the refrigerant pressure sensor electrical connector.
14. Connect the A/C tube connector (1) at the evaporator rear line assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
15. Install the battery. Refer to «Battery Replacement (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Replacement (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
16. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
17. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the battery. Refer to «Battery Replacement (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Replacement (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
4. Disconnect the front evaporator inlet line from the body retaining clip.
5. Disconnect the refrigerant pressure sensor electrical connector.
6. Disconnect and remove the A/C tube connectors from the evaporator rear line assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Disconnect the front evaporator inlet line from the evaporator rear line assembly.
8. Remove and discard O-rings.
9. Cap or tape the front evaporator inlet line.
10. Disconnect the A/C compressor line from the evaporator rear line assembly.
11. Remove and discard the O-rings.
12. Cap or tape the front evaporator line and A/C compressor line.
13. Remove the heater pipe bracket retaining nut (1) from the cowl stud.
14. Remove the thermal expansion valve (TXV) block fitting nut (2).
15. Disconnect the evaporator rear line assembly from the TXV (3).
16. Disconnect the evaporator rear line assembly from the retainer bracket stud.
17. Remove the rear evaporator line assembly from the vehicle.
18. Remove and discard the seal washers.
19. Cap or tape the TXV (3).

1. Remove the cap or tape from the TXV (3).
2. Install new seal washers to the evaporator rear line assembly. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the evaporator rear line assembly to the vehicle.
4. Connect the evaporator rear line assembly to the retainer bracket stud.
5. Connect the evaporator rear line assembly to the TXV (3).
6. Install the TXV block fitting nut (2) and tighten to 20 N.m (15 lb ft).
7. Install the heater pipe bracket retaining nut (1) to the cowl stud and tighten to 10 N.m (89 lb in).
8. Remove cap or tape from the front evaporator line and A/C compressor line.
9. Install new O-rings to the rear evaporator line assembly. Refer to «O-Ring Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
10. Connect the A/C compressor line to the evaporator rear line assembly.
11. Connect the front evaporator line to the evaporator rear line assembly.
12. Connect the A/C tube connectors onto the evaporator rear line assembly. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
13. Connect the refrigerant pressure sensor electrical connector.
14. Connect the front evaporator inlet line to the body retaining clip.
15. Install the intake manifold. Refer to «Intake Manifold Replacement»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) .
16. Install the battery. Refer to «Battery Replacement (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Replacement (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
17. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
18. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Remove the front evaporator inlet line to A/C condenser bolt.
4. Disconnect the front evaporator inlet line from the A/C condenser.
5. Cap or tape off the A/C condenser port.
6. Remove A/C refrigerant filter from the front evaporator inlet line.
7. Remove and discard the seal washer from the front evaporator inlet line.
8. Cap or tape off the front evaporator inlet line.

1. Remove the cap or the tape from the front evaporator inlet line.
2. Install a new seal washer to the front evaporator inlet line. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the A/C refrigerant filter to the front evaporator inlet line.
4. Remove the cap or tape from the A/C condenser.
5. Connect the front evaporator inlet line to the condenser.
6. Install the front evaporator inlet line to condenser bolt and tighten to 16 N.m (12 lb ft).
7. Lower the vehicle.
8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

1. J 39400-A Halogen Leak Detector
2. J 46246 Valve Core Tool. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Using the J 46246 , remove the valve core from the service port. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Install the valve core to the service port.
2. Using the J 46246 , tighten the valve core. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten: Tighten the valve core to 11 N.m (97 lb in).
3. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Leak test the fittings of the component using J 39400-A .

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the rear evaporator line assembly. Refer to «Air Conditioning Evaporator Rear Tube Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Remove the thermal expansion valve (TXV) to evaporator core mounting bolts.
4. Disconnect the TXV from the evaporator and remove from the vehicle.
5. Remove and discard the evaporator core seal washers.
6. Cap or tape off the evaporator core.

1. Remove the cap or tape from the evaporator core.
2. Install new seal washers to the evaporator core. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the TXV to the evaporator core.
4. Install the TXV to evaporator core mounting bolts and tighten to 7 N.m (62 lb in).
5. Install the rear evaporator line assembly. Refer to «Air Conditioning Evaporator Rear Tube Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

J 39400-A: Halogen Leak Detector

1. Disconnect the A/C refrigerant pressure sensor electrical connector.
2. Remove the A/C refrigerant pressure sensor from the front evaporator line.
3. Remove and discard the O-ring seal from the A/C refrigerant sensor port.

1. Install a new O-ring seal onto the A/C refrigerant pressure sensor port. Refer to «O-Ring Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the A/C refrigerant pressure sensor to the front evaporator line and tighten to 5 N.m (44 lb in).
3. Connect the A/C refrigerant pressure sensor electrical connector.
4. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the upper radiator support. Refer to «Radiator Support Replacement»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the A/C compressor hose assembly to A/C condenser fitting bolt.
4. Disconnect the A/C compressor hose assembly from the A/C condenser fitting.
5. Remove and discard the seal washer.
6. Cap or tape the A/C compressor hose assembly.
7. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
8. Remove the front evaporator inlet line bolt from the A/C condenser.
9. Disconnect the front evaporator inlet line from the A/C condenser.
10. Remove and discard the seal washer.
11. Cap or tape the front evaporator inlet line.
12. Lower the vehicle.
13. Remove the LH radiator air baffle upper retainer pin (1).
14. Remove the RH radiator air baffle upper retainer pin (1).
15. Raise the A/C condenser along the radiator to release the A/C condenser tabs from the radiator slots.
16. Remove the A/C condenser from the vehicle.

1. If replacing the condenser, add the specified amount of PAG oil directly to the condenser. Refer to «Refrigerant System Capacities»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
2. Position the A/C condenser into the vehicle.
3. Lower the A/C condenser to secure the A/C condenser tabs into the radiator slots.
4. Remove the RH radiator air baffle upper retainer pin (1).
5. Remove the LH radiator air baffle upper retainer pin (1).
6. Raise and support the vehicle.
7. Remove the cap or tape from the front evaporator inlet line.
8. Install a new seal washer onto the front evaporator inlet line. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Connect the front evaporator inlet line to the A/C condenser.
10. Install the front evaporator inlet line bolt and tighten to 16 N.m (12 lb ft).
11. Lower the vehicle.
12. Remove the cap or tape from the A/C compressor hose assembly.
13. Install a new seal washer to the A/C compressor hose assembly. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
14. Connect the A/C compressor hose assembly to the A/C condenser.
15. Install the A/C compressor hose assembly to A/C condenser bolt (1) and tighten to 16 N.m (12 lb ft).
16. Install the upper radiator support. Refer to «Radiator Support Replacement»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
17. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
18. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the heater pipe assembly. Refer to «Heater Pipes Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Remove the evaporator drain tube (1) from the HVAC module.
5. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
6. Remove the air distribution duct. Refer to «Air Distributor Duct Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Remove the retainers from the upper defogger duct on the left side window.
8. Disconnect and remove the upper defogger outlet duct.
9. Disconnect the head-up display (HUD) electrical connector.
10. Remove the HUD retaining nuts.
11. Remove the screw that secures the HUD to the steering column bracket.
12. Remove the retainer from the lower defogger outlet duct.
13. Disconnect and remove the outlet duct from the defroster duct.
14. Remove the retaining screws from the floor air outlet duct.
15. Remove the outlet duct.
16. Remove the retainers from the upper outlet duct on the right side window defogger.
17. Disconnect and remove the defogger upper outlet duct from the defogger lower outlet duct.
18. Disconnect the defogger lower outlet duct from the knee bolster bracket.
19. Disconnect the defogger lower outlet duct from the defroster duct.
20. Remove the defogger lower outlet duct.
21. Remove the SIR bracket. Refer to «Instrument Panel Inflatable Restraint Module Bracket Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
22. Remove the retaining screws from the floor air outlet duct.
23. Remove the air outlet duct.
24. Remove the defroster duct retaining screws.
25. Remove the defroster duct.
26. Disconnect the blower motor electrical connector.
27. Remove the blower motor retaining screws.
28. Remove the blower motor from the HVAC module.
29. Remove the retaining and sealing nuts from the cowl.
30. Remove the retaining bolts from the upper I/P cross vehicle beam.
31. Completely loosen the studs on the HVAC module.
32. Loosen the front LH recirculation housing retaining screw.
33. Disconnect the recirculation actuator electrical connector.
34. Disconnect the HVAC module wiring harness from the recirculation housing.
35. Remove the remaining recirculation housing retaining screws.
36. Remove the recirculation housing from the HVAC module.
37. Reposition the center console wiring harness and the corresponding electrical connectors to the sides of the HVAC module and forward of the lower tie bar.
38. Carefully remove the HVAC module from the vehicle.
39. Remove and discard the air inlet, drain and plumbing seals from the HVAC module.

1. If a new HVAC module is being installed, add the specified amount of PAG oil to the evaporator core. Refer to «Refrigerant System Capacities»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
2. Install the HVAC module studs. Tighten: Tighten the studs to 4 N.m (35 lb in).
3. Install new air inlet, drain and plumbing seals to the HVAC module.
4. Inspect the dash-mat for proper alignment to the cowl. Align if necessary.
5. Install the HVAC module into the vehicle.
6. Reposition the center console wire harness and the corresponding electrical connectors rearward of the lower tie bar.
7. Install the recirculation housing to the HVAC module.
8. Install the recirculation housing retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
9. Connect the HVAC module wiring harness to the recirculation housing.
10. Connect the recirculation actuator electrical connector.
11. Tighten the front LH recirculation housing retaining screw. Tighten: Tighten the screw to 1.6 N.m (14 lb in).
12. Align the following components to the corresponding openings on the cowl: The heater core block fitting The evaporator block fitting The HVAC module drain The HVAC module studs
13. Install the bolts retaining the HVAC module to the upper I/P cross vehicle beam. Tighten: Tighten the bolts to 5 N.m (44 lb in).
14. Install new HVAC module retaining and sealing nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
15. Install the blower motor to the HVAC module.
16. Install the blower motor retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
17. Connect the blower motor electrical connector.
18. Install the defroster duct to the HVAC module.
19. Install the defroster duct retaining screws. Tighten: Tighten the screws to 10 N.m (89 lb in).
20. Install the right floor air outlet duct.
21. Install the floor air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
22. Install the lower outlet duct to the side window defogger.
23. Connect the lower outlet duct on the side window defogger to the defroster duct.
24. Remove the SIR bracket. Refer to «Instrument Panel Inflatable Restraint Module Bracket Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
25. Connect the defogger lower outlet duct to the knee bolster bracket.
26. Connect the defogger upper outlet duct to the defogger lower outlet duct.
27. Install the retainers to the defogger upper outlet duct.
28. Install the left rear floor air outlet duct.
29. Install the floor air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
30. Connect the window defogger lower outlet duct to the defroster duct.
31. Install the defogger lower outlet duct retainer.
32. Install the screw that secures the HUD to the steering column bracket. Tighten: Tighten the screw to 3 N.m (27 lb in).
33. Install the HUD retaining nuts. Tighten: Tighten the nuts to 5 N.m (44 lb in).
34. Connect the HUD electrical connector.
35. Connect the defogger upper outlet duct.
36. Install the retainers to the upper defogger duct.
37. Install the air distribution duct. Refer to «Air Distributor Duct Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
38. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
39. Install the evaporator drain tube (1) to the HVAC module.
40. Install the heater pipe assembly. Refer to «Heater Pipes Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
41. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
42. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
43. Leak test the fittings of the component using J 39400-A .

J 39400-A Halogen Leak Detector

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove and discard the HVAC module assembly foam seal.
3. Remove the thermal expansion valve (TXV) mounting bolts.
4. Remove the TXV from the evaporator core.
5. Remove and discard the sealing washers.
6. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
7. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.
8. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.
9. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.
10. Remove the heater cover screws.
11. Remove the heater cover from the HVAC module.
12. Remove the heater core from the HVAC module.
13. Remove the HVAC module case retaining screws.
14. Separate the HVAC module upper case from the HVAC module lower case.
15. Remove the evaporator core from the HVAC module.

1. If replacing the evaporator core, add the specified amount of polyalkylene glycol (PAG) oil directly to the evaporator core. Refer to «Refrigerant System Capacities»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
2. Install a new side seal to the evaporator core.
3. Install a new upper seal to the evaporator core.
4. Install two new lower seals to the evaporator core.
5. Install the evaporator core to the HVAC module.
6. Install the HVAC module upper case to the HVAC module lower case.
7. Install the HVAC module case retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
8. Install a new foam seal to the heater core.
9. Install the heater core to the HVAC module.
10. Install the heater cover to the HVAC module.
11. Install the heater cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
12. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (1).
13. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (3).
14. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.
15. Connect the discharge temperature management (DTM) sensor electrical connectors.
16. Install new sealing washers to the evaporator core. Refer to «Sealing Washer Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
17. Install the TXV to the evaporator core.
18. Install the TXV to mounting bolts. Tighten: Tighten the bolts to 7 N.m (62 lb in).
19. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the heater pipe assembly. Refer to «Heater Pipes Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the HVAC module drain tube (1) from the HVAC module.

1. Install the HVAC module drain tube (1) to the HVAC module.
2. Install the heater pipe assembly. Refer to «Heater Pipes Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Disengage tension on the heater inlet hose clamp at the heater pipe assembly.
3. Disconnect the heater inlet hose from the heater pipe assembly.
4. Disconnect the heater inlet hose from the underhood junction box retainer clip.
5. Disengage tension on the heater inlet hose clamp at the water pump.
6. Disconnect the heater inlet hose from the water pump.
7. Remove the heater inlet hose from the vehicle.

1. Install the heater inlet hose on to the vehicle.
2. Connect the heater inlet hose to the water pump.
3. Engage tension on the heater inlet hose clamp at the water pump.
4. Connect the heater inlet hose to the underhood junction box retainer clip.
5. Connect the heater inlet hose to the heater pipe assembly.
6. Engage tension on the heater inlet hose clamp at the heater pipe assembly.
7. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

J 38185: Spring Hose Clamp Pliers

1. Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the rear evaporator line assembly. Refer to «Air Conditioning Evaporator Rear Tube Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Release and reposition the heater inlet and outlet hose clamps using the J 38185 .
5. Separate the heater hoses from heater pipes.
6. Cap or plug the open heater hoses.
7. Remove the heater pipe assembly to heater core retaining bolt (1).
8. Disconnect the heater pipe assembly from the heater pipe bracket retainer.
9. Disconnect the heater pipe assembly from the heater core.
10. Remove the heater pipe assembly from the vehicle.
11. Remove and discard the sealing washers.
12. Cap or plug the heater core.

1. Remove the cap or plug from the heater core.
2. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the heater pipe assembly and the heater core.
3. Lightly coat the new seal washers with coolant.
4. Carefully slide the new sealing washers onto the heater pipe assembly until properly seated.
5. Install the heater pipe assembly into position in the vehicle.
6. Install the heater pipe assembly to the heater core.
7. Install the heater pipe assembly retaining bolt (1)and tighten to 10 N.m (89 lb in).
8. Remove cap or plug from the heater hoses.
9. Connect heater inlet and outlet hoses to the heater pipe assembly.
10. Install the heater hose clamps into position using the J 38185: Spring Hose Clamp Pliers.
11. Install the rear evaporator line assembly. Refer to «Air Conditioning Evaporator Rear Tube Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Disengage the passenger compartment air filter housing cover retainer clips (1).
2. Remove the passenger compartment air filter housing cover.
3. Remove the passenger compartment air filter from the housing.

1. Install the passenger compartment air filter into the housing.
2. Install the passenger compartment air filter housing cover.
3. Engage the passenger compartment air filter housing cover retainer clips (1).

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the heater pipe assembly. Refer to «Heater Pipes Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Remove the evaporator drain tube (1) from the HVAC module.
5. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
6. Remove the retainers from the upper defogger duct on the left side window.
7. Disconnect and remove the upper defogger outlet duct.
8. Remove the air distribution duct. Refer to «Air Distributor Duct Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Remove the cross car air duct.
10. Disconnect the head-up display (HUD) electrical connector.
11. Remove the HUD retaining nuts.
12. Remove the screw that secures the HUD to the steering column bracket.
13. Remove the retainer from the lower defogger outlet duct.
14. Disconnect and remove the outlet duct from the defroster duct.
15. Remove the retaining screws from the floor air outlet duct.
16. Remove the outlet duct.
17. Remove the retainers from the upper outlet duct on the right side window defogger.
18. Disconnect and remove the defogger upper outlet duct from the defogger lower outlet duct.
19. Disconnect the defogger lower outlet duct from the knee bolster bracket.
20. Disconnect the defogger lower outlet duct from the defroster duct.
21. Remove the defogger lower outlet duct.
22. Remove the SIR bracket. Refer to «Instrument Panel Inflatable Restraint Module Bracket Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
23. Remove the retaining screws from the floor air outlet duct.
24. Remove the air outlet duct.
25. Remove the defroster duct retaining screws.
26. Remove the defroster duct.
27. Disconnect the blower motor electrical connector.
28. Remove the blower motor retaining screws.
29. Remove the blower motor from the HVAC module.
30. Remove the retaining and sealing nuts from the cowl.
31. Remove the retaining bolts from the upper I/P cross vehicle beam.
32. Loosen the front LH recirculation housing retaining screw.
33. Disconnect the recirculation actuator electrical connector.
34. Remove the recirculation actuator screws.
35. Remove the recirculation actuator.
36. Disconnect the HVAC module wiring harness from the recirculation housing (1).
37. Remove the remaining recirculation housing retaining screws.
38. Remove the recirculation housing from the HVAC module.
39. Disconnect and remove the air inlet door from the recirculation housing.
40. Remove and discard the foam seal from the recirculation housing.

1. Install a new foam seal to the recirculation housing.
2. Install the air inlet door to the recirculation housing.
3. Install the recirculation housing to the HVAC module.
4. Install the recirculation housing retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
5. Connect the HVAC module wiring harness to the recirculation housing (1).
6. Install the recirculation actuator.
7. Install the recirculation actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
8. Connect the recirculation actuator electrical connector.
9. Install the front LH recirculation housing retaining screw. Tighten: Tighten the screw to 1.6 N.m (14 lb in).
10. Align the following components to the corresponding openings on the cowl: The heater core joint fitting The evaporator joint fitting The HVAC module drain The HVAC module studs
11. Install the bolts retaining the HVAC module to the upper I/P cross vehicle beam. Tighten: Tighten the bolts to 5 N.m (44 lb in).
12. Install new HVAC module retaining and sealing nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
13. Install the blower motor to the HVAC module.
14. Install the blower motor retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
15. Connect the blower motor electrical connector.
16. Install the defroster duct to the HVAC module.
17. Install the defroster duct retaining screws. Tighten: Tighten the screws to 10 N.m (89 lb in).
18. Install the right floor air outlet duct.
19. Install the floor air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
20. Install the lower outlet duct to the side window defogger.
21. Connect the lower outlet duct on the side window defogger to the defroster duct.
22. Remove the SIR bracket. Refer to «Instrument Panel Inflatable Restraint Module Bracket Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
23. Connect the defogger lower outlet duct to the knee bolster bracket.
24. Connect the defogger upper outlet duct to the defogger lower outlet duct.
25. Install the retainers to the defogger upper outlet duct.
26. Install the left rear floor air outlet duct.
27. Install the floor air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
28. Install the cross car air duct.
29. Install the air distribution duct. Refer to «Air Distributor Duct Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
30. Connect the window defogger lower outlet duct to the defroster duct.
31. Install the defogger lower outlet duct retainer.
32. Install the screw that secures the HUD to the steering column bracket. Tighten: Tighten the screw to 3 N.m (27 lb in).
33. Install the HUD retaining nuts. Tighten: Tighten the nuts to 5 N.m (44 lb in).
34. Connect the HUD electrical connector.
35. Connect the defogger upper outlet duct.
36. Install the retainers to the upper defogger duct.
37. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
38. Install the evaporator drain tube (1) to the HVAC module.
39. Install the heater pipe assembly. Refer to «Heater Pipes Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
40. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/corvette/c6-2004-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
41. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
42. Use J 39400-A to leak test the fittings of the component.

1. Remove the right hand (RH) insulator panel. Refer to «Instrument Panel Insulator Panel Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
2. Disconnect the blower motor electrical connector.
3. Remove the blower motor retaining screws.
4. Remove the blower motor from the HVAC module.

1. Install the blower motor to the HVAC module.
2. Install the blower motor retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
3. Connect the blower motor electrical connector.
4. Install the RH insulator panel. Refer to «Instrument Panel Insulator Panel Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .

1. Remove the air distribution duct. Refer to «Air Distributor Duct Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the retainers from the RH defogger upper outlet duct.
3. Disconnect and remove the RH defogger upper outlet duct from the RH defogger lower outlet duct.
4. Disconnect the RH defogger lower outlet duct from the SIR bracket.
5. Disconnect the RH defogger lower outlet duct from the defroster duct.
6. Remove the RH defogger lower outlet duct.
7. Remove the windshield defroster duct retaining screws.
8. Disconnect the defroster duct from the LH defogger lower outlet duct.
9. Remove the defroster duct.

1. Install the defroster duct.
2. Connect the defroster duct to the LH defogger lower outlet duct.
3. Install the retaining screws to the windshield defroster duct. Tighten: Tighten the screws to 10 N.m (89 lb in).
4. Install the RH defogger lower outlet duct.
5. Connect the RH defogger lower outlet duct to the defroster duct.
6. Connect the RH defogger lower outlet duct to the SIR bracket.
7. Connect the RH defogger upper outlet duct to the RH defogger lower outlet duct.
8. Install the retainers to the RH defogger upper outlet duct.
9. Install the air distribution duct. Refer to «Air Distributor Duct Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
2. Remove the bolts and screws retaining the air distribution duct to the underside of the I/P assembly.
3. Remove the air distribution duct.
4. Remove the discharge temperature management (DTM) sensors from the air distribution duct.

1. Install the DTM sensors to the air distribution duct.
2. Install the air distribution duct into position on the I/P assembly.
3. Install the retaining bolts and screws to the underside of the I/P assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
4. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .

1. Remove the air distribution duct. Refer to «Air Distributor Duct Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the retainers from the side window upper defogger duct.
3. Disconnect and remove the defogger upper outlet duct.
4. Disconnect the head-up display (HUD) electrical connector.
5. Remove the HUD retaining nuts.
6. Remove the screw that secures the HUD to the steering column bracket.
7. Remove the defogger lower outlet duct retainer.
8. Disconnect and remove the defogger lower outlet duct from the defroster duct.

1. Install the defogger lower outlet duct.
2. Connect the defogger lower outlet duct to the defroster duct.
3. Install the retainer to the defogger lower outlet duct.
4. Install the screw that secures the HUD to the steering column bracket. Tighten: Tighten the screw to 3 N.m (27 lb in).
5. Install the HUD retaining nuts. Tighten: Tighten the nuts to 5 N.m (44 lb in).
6. Connect the HUD electrical connector.
7. Install and connect the defogger upper outlet duct to the defogger lower outlet duct.
8. Install the retainers to the upper defogger duct.
9. Install the air distribution duct. Refer to «Air Distributor Duct Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the air distribution duct. Refer to «Air Distributor Duct Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the retainers from the defogger upper outlet duct.
3. Disconnect and remove the defogger upper outlet duct from the defogger lower outlet duct.
4. Disconnect the defogger lower outlet duct from the SIR bracket.
5. Disconnect the defogger lower outlet duct from the defroster duct.
6. Remove the defogger lower outlet duct.

1. Install the defogger lower outlet duct.
2. Connect the defogger lower outlet duct to the defroster duct.
3. Connect the defogger lower outlet duct to the SIR bracket.
4. Connect the defogger upper outlet duct to the defogger lower outlet duct.
5. Install the retainers to the defogger upper outlet duct.
6. Install the air distribution duct. Refer to «Air Distributor Duct Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
2. Remove the retaining screws from the right floor air outlet duct.
3. Disconnect the air outlet duct from the HVAC module.
4. Remove the air outlet duct.

1. Install the air outlet duct.
2. Connect the air outlet duct to the HVAC module.
3. Install the air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
4. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .

1. Remove the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .
2. Remove the air outlet duct retaining screws.
3. Disconnect the air outlet duct from the HVAC module.
4. Remove the air outlet duct.

1. Install the air outlet duct.
2. Connect the air outlet duct to the HVAC module.
3. Install the air outlet duct retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
4. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/gauges-instrument-panels/#instrument-panel-trim-and-console-trim) .

J 39400-A Halogen Leak Detector

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove and discard the HVAC module assembly foam seal.
3. Disconnect the LH air temperature actuator electrical connector.
4. Remove the LH air temperature actuator screws.
5. Remove the LH air temperature actuator.
6. Disconnect the RH air temperature actuator electrical connector.
7. Remove the RH air temperature actuator screws.
8. Remove the RH air temperature actuator.
9. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
10. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.
11. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.
12. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.
13. Remove the heater cover screws.
14. Remove the heater cover from the HVAC module.
15. Remove the heater core from the HVAC module.
16. Remove the HVAC module case retaining screws.
17. Separate the HVAC module upper case from the HVAC module lower case.
18. Lift up on the LH and RH air temperature doors to disconnect from one another.
19. Remove the RH air temperature door from the HVAC module.

1. Install the RH air temperature door to the HVAC module.
2. Lift up on the LH and RH air temperature doors to connect to one another.
3. Install the HVAC module upper case to the HVAC module lower case.
4. Install the HVAC module case retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
5. Install a new foam seal to the heater core.
6. Install the heater core to the HVAC module.
7. Install the heater cover to the HVAC module.
8. Install the heater cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
9. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (1).
10. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (3).
11. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.
12. Connect the discharge temperature management (DTM) sensor electrical connectors.
13. Install the RH air temperature actuator.
14. Install the RH air temperature actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
15. Connect the RH air temperature actuator electrical connector.
16. Install the LH air temperature actuator.
17. Install the LH air temperature actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
18. Connect the LH air temperature actuator electrical connector.
19. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

J 39400-A Halogen Leak Detector

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove and discard the HVAC module assembly foam seal.
3. Disconnect the LH air temperature actuator electrical connector.
4. Remove the LH air temperature actuator screws.
5. Remove the LH air temperature actuator.
6. Disconnect the RH air temperature actuator electrical connector.
7. Remove the RH air temperature actuator screws.
8. Remove the RH air temperature actuator.
9. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
10. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.
11. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.
12. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.
13. Remove the heater cover screws.
14. Remove the heater cover from the HVAC module.
15. Remove the heater core from the HVAC module.
16. Remove the HVAC module case retaining screws.
17. Separate the HVAC module upper case from the HVAC module lower case.
18. Lift up on the LH and RH air temperature doors to disconnect from one another.
19. Remove the LH air temperature door from the HVAC module.

1. Install the LH air temperature door to the HVAC module.
2. Lift up on the LH and RH air temperature doors to connect to one another.
3. Install the HVAC module upper case to the HVAC module lower case.
4. Install the HVAC module case retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
5. Install a new foam seal to the heater core.
6. Install the heater core to the HVAC module.
7. Install the heater cover to the HVAC module.
8. Install the heater cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
9. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (1).
10. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (3).
11. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.
12. Connect the discharge temperature management (DTM) sensor electrical connectors.
13. Install the RH air temperature actuator.
14. Install the RH air temperature actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
15. Connect the RH air temperature actuator electrical connector.
16. Install the LH air temperature actuator.
17. Install the LH air temperature actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
18. Connect the LH air temperature actuator electrical connector.
19. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Disconnect the left-hand (LH) air temperature actuator electrical connector.
3. Remove the LH actuator retaining screws.
4. Remove the LH actuator.
5. Disconnect the mode actuator electrical connector.
6. Disconnect the right-hand (RH) air temperature actuator electrical connector.
7. Remove the actuator support bracket retaining screws.
8. Remove the actuator support bracket and actuators.
9. Remove the mode valve assembly retaining screws.
10. Disconnect the HVAC module wiring harness retainer pin (1) from the HVAC module.
11. Disconnect the wiring harness from the heater core cover wire harness retainer (2) and reposition the wiring harness aside.
12. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
13. Remove the heater core cover screws.
14. Remove the heater core cover.
15. Remove the mode valve assembly.

1. Install the mode valve assembly.
2. Install the heater core cover.
3. Install the heater core cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
4. Connect the wiring harness to the heater core cover wire harness retainer (2).
5. Connect the HVAC module wiring harness retainer pin (1) to the HVAC module.
6. Connect the DTM sensor electrical connectors.
7. Install the mode valve assembly retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
8. Install the actuator support bracket and actuators to the HVAC module.
9. Install the actuator support bracket retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
10. Connect the RH air temperature actuator electrical connector.
11. Connect the mode actuator electrical connector.
12. Install the LH actuator.
13. Install the LH actuator retaining screws.
14. Connect the LH air temperature actuator electrical connector.
15. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 3

1. Remove the air inlet assembly. Refer to «Air Inlet Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Disconnect and remove the recirculation door from the air inlet housing.

1. Install the recirculation door to the air inlet housing.
2. Install the air inlet assembly. Refer to «Air Inlet Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.
3. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.
4. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.
5. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
6. Remove the DTM sensors.
7. Remove the heater core cover screws.
8. Remove the heater core cover.

1. Install the heater core cover.
2. Install the heater core cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
3. Install the DTM sensors.
4. Connect the discharge temperature management (DTM) sensor electrical connectors.
5. Connect the wiring harness to the heater core cover wire harness retainer (1).
6. Connect the wiring harness to the heater core cover wire harness retainer (3).
7. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.
8. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove and discard the HVAC module assembly foam seal.
3. Disconnect the discharge temperature management (DTM) sensor electrical connectors.
4. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.
5. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.
6. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.
7. Remove the heater cover screws.
8. Remove the heater cover from the HVAC module.
9. Remove the heater core from the HVAC module.

1. Install a new foam seal to the heater core.
2. Install the heater core to the HVAC module.
3. Install the heater cover to the HVAC module.
4. Install the heater cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
5. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (1).
6. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (3).
7. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.
8. Connect the DTM sensor electrical connectors.
9. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/corvette/c6-2004-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Illustration Tool Number/Description J 37872 Universal Spanner Wrench J 38185 Hose Clamp Pliers J 39400-A Halogen Leak Detector J 41447 R-134A A/C Tracer Dye - Box of 24 J 42220 Universal 12V Leak Detection Lamp J 43244 Relay Puller Pliers J 43600 ACR 2000 Air Conditioning Service Center J 43872 Fluorescent Dye Cleaner J 45037 A/C Oil Injector J 45268 A/C Flushing Adapter Kit J 46246 Valve Core Tool J 46297 A/C Dye Injector Kit J 46297-12 Replacement Dye Cartridges

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

See also:
• Diagnostic System Check - Vehicle
• Control Module References
• Symptoms - HVAC Systems - Automatic
• Moving Parts and Hot Surfaces Warning
• Air Temperature Malfunction
• Cooling System Description and Operation
• Engine Fails To Reach Normal Operating Temperature
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Drive Belt Tensioner Diagnosis
• Oil Leak Diagnosis
• Air Conditioning Compressor Belt Replacement (w/o LS9)
• Vibration Analysis - Engine
• Instrument Panel Assembly Replacement
• Loss of Coolant (LS3, LS7)
• Loss of Coolant (LS9)
• Fluid Leak Diagnosis
• Transmission Fluid Leak Diagnosis
• Power Steering Fluid Leaks
• Fastener Caution
• Front Suspension Crossmember Replacement (With Z06 or ZR1)
• Tire and Wheel Removal and Installation
• Lifting and Jacking the Vehicle
• Battery Replacement (LS7 or LS9)
• Fastener Tightening Specifications
• Special Tools
• Air Conditioning (A/C) Diagnostics - Pressure Zone A
• Refrigerant System Capacities
• Heating Performance Diagnostic
• Air Conditioning Compressor Oil Diagnosis