HVAC Systems - Automatic Chevrolet Monte Carlo VI

Fastener Tightening Specifications

Fastener Tightening Specifications

Refrigerant System Capacities

Refrigerant System Capacities

Diagnostic Starting Point - Heating, Ventilation and Air Conditioning

The Heating, Ventilation and Air Conditioning (HVAC) system is divided into 2 separate sections. The first, Heating, Ventilation and Air Conditioning, has all procedures that pertain to a HVAC component or function that is not specifically associated with the manual control system. The second, HVAC Systems - Manual, has all procedures specific to the Manual control system.

Begin the system diagnosis with the Diagnostic System Check - HVAC Systems - Manual in HVAC Systems - Manual.

The Diagnostic System Check will provide the identification of the control module(s) which command the system.

The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located.

Review the Description and Operation information to help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. The HVAC Description and Operation information is divided into

1. «Air Delivery Description and Operation»(/chevrolet/monte-carlo/vi-1999-2007/remont/manual-hvac-system/#hvac-systems-manual__air-delivery-description-and-operation) in HVAC Systems - Manual
2. «Air Temperature Description and Operation»(/chevrolet/monte-carlo/vi-1999-2007/remont/manual-hvac-system/#hvac-systems-manual__air-temperature-description-and-operation) in HVAC Systems - Manual

The Air Delivery Description and Operation contains the following topics

1. HVAC Control Module
2. Air Speed
3. Air Distribution
4. Recirculation Operation

The Air temperature Description and Operation contains the following topics

1. HVAC Control Components
2. Heating and A/C Operation
3. Engine Coolant
4. A/C Cycle

Leak Testing

Tools Required

1. J 39400-A Halogen Leak Detector. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 41447 R-134a A/C Tracer Dye - Box of 24. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 42220 Universal 12V Leak Detection Lamp. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 43872 Fluorescent Dye Cleaner. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. J 46297 A/C Dye Injector Kit. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. J 46297-12 Replacement Dye Cartridges. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Refrigerant Leak Testing

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. See Special Tools .

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 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
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 fluorescent dye cleaner J 43872 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

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/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

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.

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

Follow the instructions supplied with the J 39400-A . See Special Tools .

Air Conditioning (A/C) System Performance Test

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

1. The current ambient air temperature
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

Test Description

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 air temperatures.

Air Conditioning (A/C) System Performance Test

Scheme 1

A/C Performance Table

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

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

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

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

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

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

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

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

Heating Performance Diagnostic

Heating Performance Diagnostic

Defrosting Insufficient

Defrosting Insufficient

Noise Diagnosis - Blower Motor

Noise Diagnosis - Blower Motor

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - HVAC Module

Noise Diagnosis - HVAC Module

Odor Diagnosis

Odor Diagnosis

Eliminating Air Conditioning 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 that draws outside air into the HVAC module is clear of debris.
2. Disable the 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 maximum 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 clutch operation.

Refrigerant Recovery and Recharging

Tools Required

1. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 45037 A/C Oil Injector. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Note. R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure.

Note. To avoid system damage use only R-134a dedicated tools when servicing the A/C system.

Note. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

Note. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing.

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 .

Flushing

Tools Required

1. J 43600 Air 2000 Air Conditioning Service Center. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 45268 A/C Flushing Adapter Kit. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 41447 R-134A A/C Tracer Dye - Box of 24. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 42220 Universal 12V Leak Detection Lamp. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Flushing is intended to remove the following

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

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Remove the orifice tube. Refer to «Expansion (Orifice) Tube Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
3. Connect the A/C lines with the orifice tube removed.
4. Remove the A/C compressor. Refer to «Compressor Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) or «Compressor Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
5. Install the J 45268-3 to the A/C compressor hose assembly.
6. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil. Perform the following procedure: IMPORTANT: The filter inside J 45268-1 is serviceable. Remove and discard the check valve from the filter. Service the filter with AC Delco P/N GF 470, before each flush. Connect the J 45268-1 flush filter to the suction port of the J 45268-3 flush adapter. Connect the blue hose from the J 43600 to the J 45268-1 flush filter adapter. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Connect the red hose from the J 43600 to the J 45268-3. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
7. Reverse flow refrigerant flushing is recommended for desiccant bag failure only. Perform the following procedure and replace the accumulator when the flush is complete: IMPORTANT: The filter inside J 45268-1 is serviceable. Remove and discard the check valve from the filter. Service the filter with AC Delco P/N GF 470, before each flush. Connect the J 45268-1 flush filter to the discharge port of the J 45268-3 flush adapter. Connect the blue hose from the J 43600 to the J 45268-1 flush filter adapter. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Connect the red hose from the J 43600 to the suction port of the J 45268-3. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
8. Flush the A/C system. Follow the instructions supplied with the J 43600 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
9. Remove the J 45268-3 from the A/C compressor hose assembly.
10. 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. NOTE: Refer to «Fastener Notice»(/chevrolet/monte-carlo/vi-1999-2007/remont/oem-general-information/#cautions-and-notices__fastener-notice) in Cautions and Notices. Install the A/C compressor drain plug. Tighten: Tighten the drain plug to 20 N.m (15 lb ft). IMPORTANT: Flushing will remove the fluorescent leak detection dye from the A/C system. Add one bottle of J 41447 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Add the total system capacity of PAG oil to the A/C compressor. Refer to «Refrigerant System Capacities»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-system-capacities) .
11. If you will replace the A/C compressor after flushing the system, perform the following procedure: Determine if the new service compressor is shipped with PAG oil. Refer to the «Refrigerant System Capacities»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-system-capacities) . If the service compressor is shipped with PAG oil, DO NOT drain the new PAG oil from the compressor. Deduct the amount of PAG oil shipped with the service compressor from the amount of PAG oil listed in the capacities table. Refer to «Refrigerant System Capacities»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-system-capacities) . Add the calculated amount to the compressor, as needed. If the service compressor is shipped dry, no calculation is required. Add the total system capacity of PAG oil to the compressor. Refer to «Refrigerant System Capacities»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-system-capacities) . IMPORTANT: Flushing will remove the fluorescent leak detection dye from the A/C system. Add one bottle of J 41447 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
12. Install the A/C compressor. Refer to «Compressor Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) or «Compressor Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
13. Inspect the orifice tube for debris. Clean or replace as needed. Refer to «Expansion (Orifice) Tube Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
14. Install the orifice tube. Refer to «Expansion (Orifice) Tube Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
15. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
16. Leak test the fittings using the J 42220 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Draining Procedure

1. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
2. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. 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. Properly discard the used refrigerant oil.

Balancing Procedure

1. The replacement compressor is shipped without refrigerant oil.
2. Calculate the amount of refrigerant oil required for oil balancing. Compare the following refrigerant oil capacities: The amount drained and recorded during compressor removal. The amount recommended for component replacement. Refer to «Refrigerant System Capacities»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-system-capacities) .
3. Add the greater amount of refrigerant oil to the A/C compressor.

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools .

Removal Procedure

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
3. Remove the drive belt from the A/C compressor pulley and position the drive belt aside.
4. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
6. Remove the splash shield from the right side of the engine. Refer to «Splash Shield Replacement - Engine - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
7. Remove the lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
8. Remove the A/C compressor hose bolt.
9. Disconnect the A/C compressor hose from A/C compressor.
10. Disconnect the electrical connector from the A/C compressor.
11. Remove and discard the sealing washers.
12. Remove the lower mounting bolt.
13. Remove the 2 upper mounting bolts.
14. Remove the A/C compressor from the vehicle.
15. If replacing the compressor, balance the compressor oil. Refer to «Compressor Oil Balancing»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .

Installation Procedure

1. Install the compressor drain plug (1). Tighten: Tighten the drain plug to 20 N.m (15 lb ft).
2. Install the A/C compressor to the vehicle.
3. Install the 2 upper mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Install the lower mounting bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
5. Install the new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
6. Install the A/C compressor hose assembly to the A/C compressor.
7. Install the A/C compressor hose bolt to the A/C compressor. Tighten: Tighten the bolt to 33 N.m (24 lb ft).
8. Connect the electrical connector to the A/C compressor.
9. Install the lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
10. Install the splash shield to the right side of the engine. Refer to «Splash Shield Replacement - Engine - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
11. Lower the vehicle.
12. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
13. Install the drive belt around the A/C compressor pulley. IMPORTANT: Make sure the drive belt is aligned into the proper grooves of all pulleys.
14. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
15. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
16. Using J 39400-A , leak test the fittings of the component. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

J 39400-A Halogen Leak Detector. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
3. Remove the drive belt from the A/C compressor pulley and position the drive belt aside.
4. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
6. Remove the splash shield from the right side of the engine. Refer to «Splash Shield Replacement - Engine - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
7. Remove the lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
8. Remove the A/C compressor hose bolt.
9. Disconnect the A/C compressor hose from A/C compressor.
10. Disconnect the electrical connector from the A/C compressor.
11. Remove and discard the sealing washers.
12. Remove the rear mounting bracket from the A/C compressor.
13. Remove the A/C compressor mounting nuts.
14. Remove the A/C compressor.
15. If replacing the compressor, balance the compressor oil. Refer to «Compressor Oil Balancing»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .

1. Install the compressor drain plug (1). Tighten: Tighten the drain plug to 20 N.m (15 lb ft).
2. Install the A/C compressor to the vehicle.
3. Install the A/C compressor front nuts. Tighten: Tighten the nuts to 100 N.m (74 lb ft).
4. Install the rear A/C compressor bolts. Tighten: Tighten the bolts to 31 N.m (23 lb ft).
5. Install the new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
6. Install the A/C compressor hose assembly to the A/C compressor.
7. Install the A/C compressor hose nut to the compressor. Tighten: Tighten the nut to 33 N.m (24 lb ft).
8. Connect the electrical connector to the A/C compressor.
9. Install the lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
10. Install the splash shield to the right side of the engine. Refer to «Splash Shield Replacement - Engine - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
11. Lower the vehicle.
12. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
13. Install the drive belt around the A/C compressor pulley. IMPORTANT: Make sure the drive belt is aligned into the proper grooves of all pulleys.
14. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
15. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
16. Using J 39400-A , leak test the fittings of the component. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Compressor Clutch Plate and Hub Assembly Removal (V5 - Direct Mount)

Tools Required

1. J 33027-A Clutch Hub Holding Tool. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 33013-B Hub and Drive Plate Remover/Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 41790-A Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Clamp the J 41790-A in a vise and attach the A/C compressor to the holding fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Hold the clutch hub and drive plate assembly (2) in place using the J 33027-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Remove the A/C compressor shaft nut with a 13 mm socket (1).
4. Thread the clutch plate and hub remover and installer tool hub and drive plate installer into the hub.
5. Remove the hub and drive plate assembly (1) by turning the center screw into the body of the hub and drive plate remover/installer J 33013-B and against the A/C compressor shaft.
6. Remove the shaft key and retain for reassembly.

Compressor Clutch Plate and Hub Assembly Removal (V5 - Conventional Mount)

Tools Required

1. J 33022 6-Point 13 mm Socket. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 33027-A Clutch Hub Holding Tool. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 33013-B Hub And Drive Plate Remover/Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 34992 Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Clamp the J 34992 in a vise. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Attach the A/C compressor to the holding fixture using the thumb screws.
3. Use the J 33027-A in order to prevent the clutch hub and drive plate assembly from turning. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. Use the J 33022 in order to remove the shaft nut. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. Thread the J 33013-B into the hub. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. Use a wrench in order to hold the body of the J 33013-B . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
7. Turn the center screw into the body of the J 33013-B in order to remove the clutch plate and hub assembly. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
8. Remove the shaft key. Retain the shaft key for reassembly.

Clutch Rotor and/or Bearing Removal (V5 - Direct Mount)

Tools Required

1. J 41790-A Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 41552 Compressor Pulley Puller. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 33023-A Puller Pilot. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Install the compressor onto the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Remove the clutch plate and hub assembly (2).
3. Remove the clutch rotor and bearing assembly retaining ring (3), using external snap ring pliers (1).
4. Place the J 33023-A on the clutch rotor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. Install the J 41552 down into the inner circle of slots in the rotor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Turn the compressor pulley puller clockwise in the slots to engage the puller tangs with the rotor.
6. Hold the compressor pulley puller in place and use a wrench to turn the center forcing screw against the puller pilot to remove the clutch rotor and bearing assembly.

Clutch Rotor and/or Bearing Removal (V5 - Conventional Mount)

Tools Required

1. J 6083 External Snap Ring Pliers. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 9398 Rotor Bearing Remover. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 8092 Driver Handle. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 33020 Pulley Puller. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. J 33023-A Puller Pilot. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Remove the clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal (V5 - Direct Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) or «Compressor Clutch Plate and Hub Assembly Removal (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) .
2. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Install the J 33023-A to the front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. Install the J 33020 into the inner circle of slots in the rotor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the segments between the slots in the rotor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. Hold the J 33020 in place. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Tighten the puller screw against the puller guide in order to remove the puller rotor and bearing assembly.
7. Support the rotor hub in order to prevent damage to the pulley rotor during bearing removal. Remove the forcing screw from the J 33020 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . With the tangs of the J 33020 still engaged in the rotor slots, invert the assembly onto a solid, flat surface or blocks. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
8. Use a J 9398 with the J 8092 in order to drive the bearing out of the rotor hub. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Compressor Clutch Coil Removal (V5 - Conventional Mount)

Tools Required

1. J 6083 Snap Ring Pliers #24 External. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 8433-1 Puller Bar. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 8433-3 Forcing Screw. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 33020 Pulley Puller. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. J 33023-A Puller Pilot. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. J 33025 Clutch Coil Puller Legs. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Remove the clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal (V5 - Direct Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) or «Compressor Clutch Plate and Hub Assembly Removal (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) .
2. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Install the J 33023-A to the front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. Install the J 33020 into the inner circle of slots in the rotor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the segments between the slots in the rotor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. Hold the J 33020 in place. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Tighten the puller screw against the puller guide in order to remove the puller rotor and bearing assembly.
7. Mark the location of the clutch coil terminal (1) on the compressor front head.
8. Install the J 33023-A on the front head of the compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
9. Install the J 8433-1 and the J 8433-3 with the J 33025 on the front head of the compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
10. Tighten the J 8433-3 against the J 33023-A in order to remove the clutch coil (2). See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Compressor Clutch Coil Removal (V5 - Direct Mount)

Tools Required

1. J 41790-A Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 8433 Compressor Pulley Puller. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 8433-3 Forcing Screw. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 33025 Clutch Coil Puller Legs. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. J 33023-A Puller Pilot. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Install the compressor onto the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Install the J 33023-A onto the front head of the compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Remove the compressor clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal (V5 - Direct Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) or «Compressor Clutch Plate and Hub Assembly Removal (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) .
4. Remove the compressor rotor and bearing assembly. Refer to «Clutch Rotor and/or Bearing Removal (V5 - Direct Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__clutch-rotor-andor-bearing-removal-v5) or «Clutch Rotor and/or Bearing Removal (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__clutch-rotor-andor-bearing-removal-v5) .
5. Mark the clutch coil terminal location (2) on the compressor front head.
6. Install the J 33025 onto the J 8433 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
7. Install the J 8433 onto the compressor clutch coil (1) and tighten the puller leg bolts. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
8. Tighten the center forcing screw J 8433-3 of the compressor pulley puller J 8433 against the puller pilot to remove the compressor clutch coil from the compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Compressor Control Valve Assembly Removal (V5 - Direct Mount)

Tools Required

J 41790-A Compressor Holding Fixture. See Special Tools .

1. Install the compressor onto the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Remove the compressor control valve retaining ring using internal snap ring pliers.
3. Remove the compressor control valve from the compressor.

Compressor Control Valve Assembly Removal (V5 - Conventional Mount)

Tools Required

J 5403 Snap Ring Pliers. See Special Tools .

1. Remove the control valve retaining ring using the J 5403 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Remove the control valve assembly (5).

Compressor Pressure Relief Valve Removal (V5 - Direct Mount)

Tools Required

J 41790-A Compressor Holding Fixture. See Special Tools .

1. Install the compressor onto the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Remove the pressure relief valve from the rear head of the compressor.

Compressor Pressure Relief Valve Removal (V5 - Conventional Mount)

Tools Required

J 41790-A Compressor Holding Fixture. See Special Tools .

1. Install the compressor into the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Remove the pressure relief valve (2) from the rear head of the compressor.

Compressor Control Valve Assembly Install (V5 - Direct Mount)

Tools Required

J 41790-A Compressor Holding Fixture. See Special Tools .

1. Coat the control valve O-rings with clean 525 viscosity refrigeration oil.
2. Push the compressor control valve into the compressor with thumb pressure.
3. Using internal snap ring pliers, install the compressor control valve retaining ring. Ensure that the retaining ring is properly seated in the ring groove.
4. Remove the compressor from the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Compressor Control Valve Assembly Install (V5 - Conventional Mount)

Tools Required

J 5403 Snap Ring Pliers. See Special Tools .

1. Coat the O-rings with 525 viscosity refrigeration oil.
2. Using thumb pressure, push the O-rings in place.
3. Install the valve into the case.
4. Using the J 5403 , install the valve retaining ring (5) with the high point of the curved sides against the valve housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. Perform a leak test. Refer to «Compressor Leak Testing (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-leak-testing-v5-conventional) or «Compressor Leak Testing (CVC7)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-leak-testing-cvc7) .

Compressor Clutch Plate/Hub Assembly Install (V5 - Direct Mount)

Tools Required

1. J 33013-B Hub and Drive Plate Remover/ Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 33027-A Clutch Hub Holding Tool. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 33017 Pulley and Bearing Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 41790-A Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Install the shaft key into the hub key groove (4) approximately 3.2 mm (1/8 in) out of the keyway. The shaft key is curved slightly to provide an interference fit in the hub key groove.
2. Clean the surfaces of the clutch plate (1) and the clutch rotor (2) before installing the clutch plate and hub assembly.
3. Align the shaft key with the shaft keyway in the clutch plate and the hub assembly and place onto the compressor shaft (3).
4. Remove the J 33013-B . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Remove the center screw from the body of the hub and drive plate installer. Install the center screw into the opposite end of the hub and drive plate installer.
5. Install the J 33013-B and bearing tools (1) onto the clutch plate (3) and the hub assembly (2). See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the end of the compressor shaft. Thread the center screw several turns onto the end of the compressor shaft. Do not tighten the center screw on the compressor shaft.
6. Hold the center screw with a wrench. Tighten the hex portion of the hub and drive plate installer body several turns. Remove the hub and drive plate installer from the clutch plate and hub. Make sure that the shaft key is still in place in the keyway.
7. Reinstall the J 33013-B . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
8. Place a feeler gage between the clutch plate and the clutch rotor.
9. Tighten the hex portion of the hub and drive plate installer until the air gap between the clutch plate and clutch rotor is 0.40 mm (0.015 in). Make sure that the air gap is even all around the clutch plate and hub assembly.
10. Remove the J 33013-B . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
11. Hold the clutch plate and hub assembly (2) with the J 33027-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
12. Install the compressor shaft nut. Tighten: Tighten the compressor shaft nut to 17 N.m (13 lb ft).
13. Spin the pulley rotor by hand to make sure the rotor is not rubbing against the clutch drive plate.
14. Remove the compressor from the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Compressor Clutch Plate/Hub Assembly Install (V5 - Conventional Mount)

Tools Required

1. J 33013-B Hub and Drive Plate Remover/Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 33022 6-Shaft Nut Socket - 13mm. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 33027-A Clutch Hub Holding Tool. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 34992 Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Install the compressor into the J 34992 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Install the shaft key (4) into the key groove of the clutch plate and hub (1). Allow the key to project 3.2 mm (0.126 in) out of the key groove. The shaft key is curved slightly in order to provide an interference fit in the key groove of the hub.
3. Clean the frictional surfaces of the clutch plate and hub and the clutch pulley rotor (2).
4. Align the shaft key with the shaft keyway (3).
5. Place the clutch plate and hub assembly onto the compressor shaft.
6. Remove the center screw from the J 33013-B . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
7. Reverse the body direction of the center screw of the J 33013-B . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
8. Install the J 33013-B with the bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
9. Back off the body of the J 33013-B in order to allow the center screw to be threaded onto the end of the compressor shaft. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
10. Hold the center screw of the J 33013-B with a wrench. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
11. Tighten the hex portion of the body of the J 33013-B in order to press the hub onto the shaft. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
12. Tighten the body of the J 33013-B several turns. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
13. Remove the J 33013-B . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
14. Verify that the shaft key remains in the keyway before installing the clutch plate and hub assembly to the final position.
15. Ensure that the gap between the frictional surfaces of the clutch plate and the clutch rotor is within 0.40-0.50 mm (0.016-0.020 in).
16. Remove the J 33013-B . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
17. Verify that the shaft key is even with or slightly above the clutch hub.
18. Install the shaft nut.
19. Hold the clutch plate and hub assembly with the J 33027-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
20. Tighten the shaft nut against the crankshaft shoulder, using a 17.5 N.m (12.5 lb ft) torque wrench and the J 33022 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Tighten: Tighten the nut to 16.5 N.m (12 lb ft).
21. Spin the pulley rotor by hand in order to verify that the rotor does not rub the clutch drive plate.

Clutch Rotor and/or Bearing Install (V5 - Direct Mount)

Tools Required

1. J 33013-B Hub and Drive Plate Remover/Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 33017 Pulley and Bearing Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 41790-A Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Position the clutch rotor and bearing assembly (2) onto the compressor.
2. Position the J 33017 and bearing (1) from the J 33013-B directly over the inner race of the bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Place the washer (3) onto the body of J 33013-B . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. Remove the center screw from the body of the hub and drive plate installer.
5. Install the center screw into the opposite end of the hub and drive plate installer.
6. Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the end of the compressor shaft.
7. Thread the center screw several turns onto the end of the compressor shaft. Do not tighten the center screw on the compressor shaft.
8. Hold the center screw with a wrench.
9. Tighten the hex portion of the hub and drive plate installer body several turns.
10. Remove the J 33013-B from the clutch rotor and bearing assembly. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
11. Ensure that the clutch rotor and bearing (2) is pressed onto the nose of the compressor far enough to clear the groove for the retaining ring. If the clutch rotor and bearing does not clear the groove, repeat steps 7, 8 and 9.
12. Install the clutch rotor and bearing retaining ring (3) using external snap ring pliers (1). Ensure that the chamfer side of the retaining ring is facing up when the retaining ring is being installed.
13. Install the clutch plate and hub assembly.
14. Remove the compressor from the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Clutch Rotor and/or Bearing Install (V5 - Conventional Mount)

Tools Required

1. J 6083 External Snap Ring Pliers. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 8092 Driver Handle
3. J 8433-1 Puller Bar. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 8433-3 Forcing Screw. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. J 9481-A Bearing Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. J 21352-A Support Block. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
7. J 33017 Pulley And Bearing Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
8. J 33019 Pulley Bearing Staking Tool. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
9. J 33023-A Puller Pilot. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
10. J 34992 Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during the bearing installation. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Align the new bearing with the hub bore.
3. Using the J 9481-A and the J 8092 , drive the bearing into the hub. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . The J 9481-A applies force to the outer race of the bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. Place the J 33019 and the staking pin in the hub bore. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support of the hub under the location of the staking pin. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide of the J 33019 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
7. Using care in order to prevent injury, strike the staking pin of the J 33019 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Properly position the stake pin in the guide after each impact on the pin.
8. Continue to strike the pin of the J 33019 until a stake, similar to the original stake, is formed down to, but not touching, the bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
9. Stake 3 places 120 degrees apart.
10. With the compressor mounted to the J 34992 , position the rotor and bearing assembly on the front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
12. Position the J 8433-1 on the J 33023-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
13. Assemble the 2 through bolts and the washers of the J 34992 through the slots of the J 8433-1 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
14. Thread the 2 through bolts into the J 34992 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Ensure that the thread of the through bolts engages the full thickness of the J 34992 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
15. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the front head of the compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
16. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following steps: Loosen the J 8433-3 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
17. Install the rotor and bearing assembly retainer ring using the J 6083 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
18. Install the clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal (V5 - Direct Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) or «Compressor Clutch Plate and Hub Assembly Removal (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) .

Compressor Clutch Coil Install (V5 - Conventional Mount)

Tools Required

1. J 8433-1 Puller Bar. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 8433-3 Forcing Screw. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 33024 Clutch Coil Installer Adapter. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 34992 Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. J 33025 Clutch Coil Puller Legs. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Place the clutch coil assembly on the front head with the terminals positioned at the marked location.
2. Place the J 33024 over the internal opening of the clutch coil housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Align the J 33024 with the compressor front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. Center the J 8433-1 on the countersunk center hole of the J 33024 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. Install the through bolts and the washers of the J 34992 through the slots in the J 8433-1 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. Thread the through bolts into the J 33025 in order to achieve full fixture thickness. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
7. Turn the J 8433-3 of the J 8433-1 in order to force the clutch coil onto the head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
8. With the compressor still mounted to the J 34992 and the coil seated on the front head, stake the front head using a drift punch with a diameter of 3.175 mm (0.125 in). See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
9. Stake the front head at 3 places 120 degrees apart in order to ensure that the clutch coil remains in position.
10. Ensure that the stake size is only one half of the area of the punch tip and only 0.28-0.35 mm (0.010-0.015 in) in depth.
11. With the compressor mounted to the J 34992 , position the rotor and bearing assembly on the front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
12. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
13. Position the J 8433-1 on the J 33023-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
14. Assemble the 2 through bolts and the washers of the J 34992 through the slots of the J 8433-1 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
15. Thread the 2 through bolts into the J 34992 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Ensure that the thread of the through bolts engages the full thickness of the J 34992 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
16. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the front head of the compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
17. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following steps: Loosen the J 8433-3 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
18. Install the rotor and bearing assembly retainer ring using the J 6083 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
19. Install the clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal (V5 - Direct Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) or «Compressor Clutch Plate and Hub Assembly Removal (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) .
20. Install the shaft nut.

Compressor Clutch Coil Install (V5 - Direct Mount)

Tools Required

1. J 33024 Clutch Coil Installer Adapter. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 33025 Clutch Coil Puller Legs. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 8433 Compressor Pulley Puller. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 8433-3 Forcing Screw. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. J 41790-A Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. J 42136 A/C Lip Seal Remover. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Place the clutch coil assembly (1) on the front head with the clutch coil terminal at the positioned at the mark made during disassembly.
2. Place the J 33024 over the internal opening of the clutch coil housing and align installer with the compressor front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Install the J 8433-3 into the J 8433 and center the screw in the countersunk center hole of the J 33024 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. Install the 4 inch through bolts and washers from the J 42136 tool kit into the J 33025 and attach them to the compressor mounting bosses. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. Turn the center forcing screw of the J 8433 to press the clutch coil onto the front head until the clutch coil is fully seated. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Make sure the clutch coil and the J 33024 stay in-line with each other while pressing the clutch coil onto the compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. Install the compressor clutch rotor and bearing assembly. Refer to «Clutch Rotor and/or Bearing Install (V5 - Direct Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__clutch-rotor-andor-bearing-install-v5) or «Clutch Rotor and/or Bearing Install (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__clutch-rotor-andor-bearing-install-v5) .
7. Install the compressor clutch plate and hub assembly. Refer to «Compressor Clutch Plate/Hub Assembly Install (V5 - Direct Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-platehub-assembly-install-v5) or «Compressor Clutch Plate/Hub Assembly Install (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-platehub-assembly-install-v5) .
8. Remove the compressor from the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Compressor Pressure Relief Valve Install (V5 - Direct Mount)

Tool Required

J 41790-A Compressor Holding Fixture. See Special Tools .

1. Clean the pressure relief valve seat area of the rear head.
2. Lubricate the O-ring of the new pressure relief valve with clean 525 viscosity refrigerant oil.
3. Install the new pressure relief valve into the compressor. Tighten: Tighten the pressure relief valve to 9 N.m (80 lb in).
4. Remove the compressor from the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Compressor Pressure Relief Valve Install (V5 - Conventional Mount)

1. Clean the valve seat area on the rear head.
2. Lubricate the O-ring of the new pressure relief valve and the O-ring assembly using new 525 viscosity refrigerant oil.
3. Install the new pressure relief valve (2). Tighten: Tighten the valve to 9 N.m (80 lb in).
4. Perform a leak test. Refer to «Compressor Leak Testing (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-leak-testing-v5-conventional) or «Compressor Leak Testing (CVC7)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-leak-testing-cvc7) .

Compressor Leak Testing (V5 - Conventional Mount)

Tools Required

1. J 39400-A Halogen Leak Detector. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 39893 Pressure Test Adapter. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. With the sealing washers in place, install the J 39893 on the rear head of the compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Connect the gage charging lines and the J 43600 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Pressurize the suction and the high-side of the compressor using R-134a refrigerant.
4. With the compressor in a horizontal position, rotate the compressor shaft several turns by hand in the operating direction.
5. Using the J 39400-A , inspect for leaks at the following locations: The pressure relief valve The rear head switch The front head seal The rear head seal The through bolt head gaskets The compressor shaft seal
6. Perform the measures necessary to correct any external leaks found.
7. Inspect for leaks again following any repair.
8. Recover the refrigerant.
9. Disconnect the hoses from the J 39893 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
10. Remove the J 39893 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Compressor Leak Testing (CVC7)

Tools Required

1. J 39400-A Halogen Leak Detector. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 39893 Pressure Test Adapter. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. With the sealing washers in place, install the J 39893 on the rear head of the compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Connect the gage charging lines and the J 43600 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Pressurize the suction and the high-side of the compressor with R-134a refrigerant.
4. With the compressor in a horizontal position, rotate by hand the compressor shaft in the operating direction.
5. Rotate the shaft several times.
6. Using the J 39400-A , check for leaks at the following locations: Pressure relief valve Rear head switch Front head seals Rear head seals Through bolt head gaskets Compressor shaft seal
7. Perform the measures necessary to correct any external leaks found.
8. Recheck for leaks following any repair.
9. Recover the refrigerant.
10. Disconnect the hoses from the J 39893 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
11. Remove the J 39893 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

Tools Required

1. J 41790-A Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 41552 Compressor Pulley Puller. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. J 33023-A Puller Pilot. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 33013-B Hub and Drive Plate Remover/Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. J 33017 Pulley and Bearing Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Remove the A/C compressor. Refer to «Compressor Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) or «Compressor Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
2. Install the compressor onto the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Remove the clutch plate and hub assembly (2).
4. Remove the clutch rotor and bearing assembly retaining ring (3), using external snap ring pliers (1).
5. Place the J 33023-A on the clutch rotor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. Install the J 41552 down into the inner circle of slots in the rotor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Turn the compressor pulley puller clockwise in the slots to engage the puller tangs with the rotor.
7. Hold the compressor pulley puller in place and use a wrench to turn the center forcing screw against the puller pilot to remove the clutch rotor and bearing assembly.

1. Position the clutch rotor and bearing assembly (2) onto the compressor.
2. Position the J 33017 and bearing (1) from the J 33013-B directly over the inner race of the bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Place the washer (3) onto the body of J 33013-B . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. Remove the center screw from the body of the hub and drive plate installer.
5. Install the center screw into the opposite end of the hub and drive plate installer.
6. Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the end of the compressor shaft.
7. Thread the center screw several turns onto the end of the compressor shaft. Do not tighten the center screw on the compressor shaft.
8. Hold the center screw with a wrench.
9. Tighten the hex portion of the hub and drive plate installer body several turns.
10. Remove the J 33013-B from the clutch rotor and bearing assembly. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
11. Ensure that the clutch rotor and bearing (2) is pressed onto the nose of the compressor far enough to clear the groove for the retaining ring. If the clutch rotor and bearing does not clear the groove, repeat steps 7, 8 and 9.
12. Install the clutch rotor and bearing retaining ring (3) using external snap ring pliers (1). Ensure that the chamfer side of the retaining ring is facing up when the retaining ring is being installed.
13. Install the clutch plate and hub assembly.
14. Remove the compressor from the J 41790-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
15. Install the A/C compressor. Refer to «Compressor Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) or «Compressor Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .

Clutch Rotor and/or Bearing Replacement (V-5 Conventional Mount)

Tools Required

1. J 6083 External Snap Ring Pliers. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 8092 Universal Driver Handle
3. J 8433-1 Puller Bar. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. J 8433-3 Forcing Screw. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. J 9398 Rotor Bearing Remover. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. J 9481-A Bearing Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
7. J 21352-A Support Block. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
8. J 33017 Pulley and Bearing Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
9. J 33019 Pulley Bearing Staking Tool. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
10. J 33023-A Puller Pilot. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
11. J 34992 Compressor Holding Fixture. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
12. J 33020 Pulley Puller. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Remove the A/C compressor. Refer to «Compressor Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) or «Compressor Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
2. Remove the clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal (V5 - Direct Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) or «Compressor Clutch Plate and Hub Assembly Removal (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-plate-and-hub-assembly) .
3. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. Install the J 33023-A to the front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. Install the J 33020 into the inner circle of slots in the rotor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the segments between the slots in the rotor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
7. Hold the J 33020 in place. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Tighten the puller screw against the puller guide in order to remove the puller rotor and bearing assembly.
8. Support the rotor hub in order to prevent damage to the pulley rotor during bearing removal. Remove the forcing screw from the J 33020 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . With the tangs of the J 33020 still engaged in the rotor slots, invert the assembly onto a solid, flat surface or blocks. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
9. Use a J 9398 with the J 8092 in order to drive the bearing out of the rotor hub. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during the bearing installation. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. Align the new bearing with the hub bore.
3. Using the J 9481-A and the J 8092 , drive the bearing into the hub. The J 9481-A applies force to the outer race of the bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
4. Place the J 33019 and the staking pin in the hub bore. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the location of the staking pin. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
6. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide of the J 33019 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
7. Using care in order to prevent injury, strike the staking pin of the J 33019 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Properly position the stake pin in the guide after each impact on the pin.
8. Continue to strike the pin of the J 33019 until a stake, similar to the original stake, is formed down to, but not touching, the bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
9. Stake 3 places 120 degrees apart.
10. With the compressor mounted to the J 34992 , position the rotor and bearing assembly on the front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
12. Position the J 8433-1 on the J 33023-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
13. Assemble the 2 through bolts and the washers of the J 34992 through the slots of the J 8433-1 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
14. Thread the 2 through bolts into the J 34992 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Ensure that the thread of the through bolts engages the full thickness of the J 34992 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
15. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the front head of the compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
16. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following steps: Loosen the J 8433-3 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) . Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the front head. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
17. Install the rotor and bearing assembly retainer ring using the J 6083 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
18. Install the clutch plate and hub assembly. Refer to «Compressor Clutch Plate/Hub Assembly Install (V5 - Direct Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-platehub-assembly-install-v5) or «Compressor Clutch Plate/Hub Assembly Install (V5 - Conventional Mount)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__compressor-clutch-platehub-assembly-install-v5) .
19. Install the A/C compressor. Refer to «Compressor Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) or «Compressor Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .

1. Remove the seal washer from the A/C refrigerant component.
2. Inspect the seal washer for signs of damage to help determine the root cause of the failure.
3. Inspect the A/C refrigerant components for damage or burrs. Repair if 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. Remove the cap or tape from the A/C refrigerant components.
3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
4. Carefully install the new seal washer onto the A/C refrigerant component. 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 For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). For banjo style fittings remove the bolt retaining the banjo type fitting.
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. For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification.

J 39400-A Halogen Leak Detector. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly.
3. Remove the A/C compressor hose nut from the A/C condenser.
4. Remove the A/C compressor hose from the A/C condenser.
5. Remove the A/C compressor hose nut from the accumulator.
6. Remove the A/C compressor hose from the accumulator.
7. Remove the lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
8. Remove the A/C compressor hose bolt from the A/C compressor.
9. Remove the A/C compressor hose from the A/C compressor.

1. Install new sealing washers onto the A/C compressor hose assembly. Refer to «Sealing Washer Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
2. Install the A/C compressor hose to the A/C compressor.
3. Install the A/C compressor hose bolt to the A/C compressor. Tighten: Tighten the bolt to 33 N.m (24 lb ft).
4. Install the lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
5. Install the new O-ring seal to the A/C compressor hose assembly. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
6. Install the A/C compressor hose to the accumulator.
7. Install the A/C compressor hose nut onto the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
8. Install the A/C compressor hose to the condenser.
9. Install the A/C compressor hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
10. Install the air cleaner assembly.
11. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
12. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

J 39400-A Halogen Leak Detector. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly.
3. Remove the A/C compressor hose nut from the condenser.
4. Disconnect the A/C compressor hose from the condenser.
5. Remove the A/C compressor hose nut from the accumulator.
6. Remove the A/C compressor hose from the accumulator.
7. Remove the lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
8. Remove the A/C compressor hose nut from the A/C compressor. Remove the A/C compressor hose from the A/C compressor.

1. Install new sealing washers onto the A/C compressor hose assembly. Refer to «Sealing Washer Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
2. Install the A/C compressor hose to the A/C compressor.
3. Install the A/C compressor hose nut to the A/C compressor. Tighten: Tighten the nut to 33 N.m (24 lb ft).
4. Install the lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
5. Install the new O-ring seal to the A/C compressor hose assembly. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
6. Install the A/C compressor hose to the accumulator.
7. Install the A/C compressor hose nut to the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
8. Install the A/C compressor hose to the condenser.
9. Install the A/C compressor hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
10. Install the air cleaner assembly.
11. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
12. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

J 39400-A Halogen Leak Detector. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly. Refer to one of the following procedures
3. Remove the cross vehicle brace. Refer to «Brace Replacement - Cross Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
4. Remove the vacuum brake booster. Refer to «Vacuum Brake Booster Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Vacuum Brake Booster Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
5. Remove the condenser tube from the support bracket.
6. Remove the lower radiator air baffle. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
7. Remove the condenser tube nut from the condenser.
8. Disconnect the condenser tube from the condenser.
9. Lower the vehicle.
10. Disconnect the electrical connector from the A/C refrigerant pressure sensor.
11. Loosen the evaporator tube nut from the condenser tube.
12. Disconnect the evaporator tube from the condenser tube.
13. Remove the condenser tube.
14. Remove and discard the O-ring.
15. Remove the A/C pressure sensor from the condenser tube.

1. Install the A/C pressure sensor to the condenser tube.
2. Install the new O-ring onto the condenser tube. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
3. Install the condenser tube to the support bracket.
4. Connect the condenser tube to the evaporator tube.
5. Tighten the evaporator inlet tube nut. Tighten: Tighten the nut to 27 N.m (20 lb ft).
6. Connect the electrical connector to the A/C refrigerant pressure sensor.
7. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
8. Connect the condenser tube to the condenser. Tighten the condenser tube nut. Tighten: Tighten the nut to 27 N.m (20 lb ft).
9. Install the lower radiator air baffle. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
10. Install the vacuum brake booster. Refer to «Vacuum Brake Booster Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Vacuum Brake Booster Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
11. Install the cross vehicle brace. Refer to «Brace Replacement - Cross Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
12. Install the air cleaner assembly. Refer to one of the following procedures
13. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
14. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

J 39400-A Halogen Leak Detector. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly.
3. Remove the vacuum brake booster. Refer to «Vacuum Brake Booster Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Vacuum Brake Booster Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
4. Remove the condenser tube from the support bracket.
5. Disconnect the evaporator tube nut from the condenser tube.
6. Disconnect the evaporator tube from the condenser tube.
7. Remove the A/C line block fitting bolt from evaporator.
8. Disconnect the evaporator tube from the evaporator.
9. Remove the O-ring and discard.

1. Replace the O-ring seals on the evaporator tube and accumulator tube. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
2. Connect the evaporator tube to the condenser tube.
3. Connect the evaporator tube to the evaporator.
4. Install the accumulator tube to the evaporator block fitting.
5. Install the A/C line block fitting bolt to the evaporator. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
6. Tighten the evaporator tube nut to the condenser tube. Tighten: Tighten the nut to 27 N.m (20 lb ft).
7. Install the condenser tube to the support bracket.
8. Install the vacuum brake booster. Refer to «Vacuum Brake Booster Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Vacuum Brake Booster Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
9. Install the air cleaner assembly.
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
11. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

J 39400-A Halogen Leak Detector. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly.
3. Remove the vacuum brake booster. Refer to «Vacuum Brake Booster Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Vacuum Brake Booster Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
4. Remove the brake pressure modulator valve bracket. Refer to «Brake Pressure Modulator Valve (BPMV) Bracket Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/anti-locktraction-control/#antilock-brake-system) in Antilock Brake System.
5. Remove the accumulator clip.
6. Loosen the accumulator tube nut at the accumulator (2).
7. Disconnect the accumulator tube from the accumulator.
8. Remove the accumulator tube to evaporator core block fitting bolt.
9. Disconnect the accumulator tube from the evaporator.
10. Remove the accumulator tube.
11. Remove the O-ring seal and discard.

1. Replace the O-ring seal on the accumulator tube. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
2. Install the accumulator tube.
3. Connect the accumulator tube to the evaporator.
4. Install the accumulator tube to evaporator core block fitting bolt. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
5. Connect the accumulator tube to the accumulator (2).
6. Tighten the accumulator tube nut at the accumulator. Tighten: Tighten the nut to 47 N.m (35 lb ft).
7. Install the accumulator clip.
8. Install the brake pressure modulator valve bracket. Refer to «Brake Pressure Modulator Valve (BPMV) Bracket Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/anti-locktraction-control/#antilock-brake-system) in Antilock Brake System.
9. Install the vacuum brake booster brakes. Refer to «Vacuum Brake Booster Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Vacuum Brake Booster Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
10. Install the air cleaner assembly.
11. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
12. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

J 39400-A Halogen Leak Detector. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Remove the evaporator tube from the condenser tube. Refer to «Condenser Tube Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
3. Measure 110 mm (4.3 in) and mark the condenser tube.
4. Cut the condenser tube.
5. Measure 60 mm (2.4 in) and mark the condenser tube.
6. Cut the condenser tube.
7. Remove any burrs from the cut ends of the condenser tube.
8. Remove the O-ring from the A/C refrigerant filter.
9. Install 1 flare nut and 1 ferrule to the condenser tube with the tapered end of the ferrule facing the flare nut.
10. Install the A/C refrigerant filter to the condenser tube with the arrow pointing toward the evaporator. Tighten: Tighten the A/C refrigerant filter flare nut to 15 N.m (11 lb ft).
11. Install 1 flare nut and 1 ferrule to the other half of the condenser tube with the tapered end of the ferrule facing the flare nut.
12. Install the A/C refrigerant filter to the condenser tube. Tighten: Tighten the A/C refrigerant filter flare nut to 15 N.m (11 lb ft).
13. Loosen the flare nuts and remove the A/C refrigerant filter from the condenser tube.
14. Lubricate and install the O-ring to each end of the condenser tube. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
15. Install the A/C refrigerant filter to the condenser tube with the arrow pointing toward the evaporator. Tighten: Tighten the A/C refrigerant filter flare nuts to 15 N.m (11 lb ft).
16. Install the evaporator tube to the condenser tube. Refer to «Condenser Tube Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
17. Install the air cleaner assembly.
18. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
19. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

J 39400-A Halogen Leak Detector. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Remove the left front fender upper diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
3. Remove the air cleaner assembly.
4. Loosen the A/C refrigerant filter flare nuts.
5. Remove the A/C refrigerant filter from the condenser tube.
6. Discard the O-ring.

1. Remove the cap or the tape from the ends of the condenser tubes.
2. Lubricate and install new O-rings to each end of the condenser tube. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
3. Install the A/C refrigerant filter to the condenser tube with the arrow pointing toward the evaporator. Tighten: Tighten the A/C refrigerant filter flare nuts to 15 N.m (11 lb ft).
4. Install the air cleaner assembly.
5. Install the left front fender upper diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
6. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
7. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

J 26549-E Orifice Tube Remover. See Special Tools .

1. Remove the condenser tube. Refer to «Condenser Tube Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
2. Use J 26549-E in order to remove the expansion orifice tube. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
3. Inspect the expansion orifice tube for the following conditions and clean or replace with a new tube as indicated: Broken plastic frame (1); replace the tube. Inlet filter (3) damaged or plugged with fine gritty material; replace the tube. Inlet filter (3) coated with metal chips, flakes, or slivers; remove the coating with low pressure shop air ONLY and reuse if the filter is cleaned satisfactorily. Do NOT reuse the O-ring seals (2).

1. If you reuse the orifice tube, install new O-ring seals (2).
2. Carefully grasp the edge of the expansion orifice tube (1) without touching the inlet filter (3) and insert the expansion orifice tube into the condenser tube until fully seated.
3. Install the condenser tube. Refer to «Condenser Tube Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .

1. Remove the underhood lower relay cover.
2. Remove the A/C compressor control relay from the electrical center.

1. Install the A/C compressor control relay into the electrical center.
2. Install the underhood lower relay cover.

J 39037 Charge Valve Octagon Socket. See Special Tools .

1. Remove the service port cap.
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
3. Use the J 39037 to remove the service port. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Replace the O-ring. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
2. Install the service port valve. Tighten: Tighten the valve to 11 N.m (98 lb in).
3. Evacuate and charge the system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
4. Leak test the A/C service port. Refer to «Leak Testing»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__leak-testing) .
5. Install the service port cap.

J 39400-A Halogen Leak Detector. See Special Tools .

1. Remove the air cleaner assembly.
2. Disconnect the electrical connector from the A/C refrigerant pressure sensor.
3. Remove the A/C refrigerant pressure sensor from the condenser tube.

1. Replace the O-ring seal for the A/C refrigerant pressure sensor. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
2. Install the A/C refrigerant pressure sensor to the condenser tube. Tighten: Tighten the sensor to 4.7 N.m (41 lb in).
3. Connect the electrical connector to the A/C refrigerant pressure sensor.
4. Install the air cleaner assembly.
5. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

J 39400-A Halogen Leak Detector. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Remove the radiator. Refer to «Radiator Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
3. Remove the liquid line nut from the condenser and position the liquid line aside.
4. Remove the A/C compressor line nut from the condenser and position the A/C compressor line aside.
5. Tilt the top of the condenser to the rear of the vehicle and lift up to remove the condenser.
6. Ensure the lower rubber mounts stay in place in the vehicle.
7. Remove the upper rubber mounts from the condenser.

1. If replacing the condenser, add refrigerant oil to the condenser. Refer to «Refrigerant System Capacities»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-system-capacities) for system capacity information.
2. Install the upper rubber mounts on to the condenser.
3. Install the lower ends of the condenser in to the lower rubber mounts. IMPORTANT: Ensure the upper rubber mounts stay in place on the condenser.
4. Tilt the top of the condenser in to place.
5. Install new O-ring seals onto the A/C compressor hose and the condenser tube. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
6. Install the liquid line to the condenser. Tighten the liquid line nut to the condenser. Tighten: Tighten the nut to 27 N.m (20 lb ft).
7. Install the A/C compressor hose to the condenser.
8. Install the A/C compressor hose block fitting nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
9. Install the radiator. Refer to «Radiator Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
11. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

J 39400-A Halogen Leak Detector. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly.
3. Loosen the suction hose nut at the accumulator.
4. Remove the suction hose from the accumulator.
5. Loosen the A/C compressor hose nut from the accumulator.
6. Remove the A/C compressor hose from the accumulator.
7. Remove the accumulator bracket bolt.
8. Remove the accumulator.

1. If replacing the accumulator, add refrigerant oil to the accumulator. Refer to «Refrigerant System Capacities»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-system-capacities) for system capacity information.
2. Install the accumulator.
3. Install the accumulator bracket bolt. Tighten: Tighten the bolt to 4 N.m (36 lb in).
4. Install new O-ring seals onto the A/C compressor hose and the suction hose. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
5. Install the A/C compressor hose to the accumulator.
6. Install the A/C compressor hose nut to the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
7. Connect the suction hose to the accumulator
8. Tighten the suction hose nut. Tighten: Tighten the nut to 47 N.m (35 lb ft).
9. Install the air cleaner assembly.
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
11. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

HVAC Module Assembly Replacement

Tools Required

1. J 39400-A Halogen Leak Detector. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .
2. J 38185 Hose Clamp Pliers

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
3. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
4. Remove the cross vehicle brace. Refer to «Brace Replacement - Cross Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front end.
5. Remove the accumulator tube to evaporator core block fitting bolt.
6. Disconnect the accumulator tube from the evaporator.
7. Disconnect the evaporator tube from the evaporator.
8. Remove the O-rings seals and discard.
9. Use J 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
10. Disconnect the inlet and outlet heater hose from the heater core.
11. Remove the IP lower trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
12. Remove the retaining screw (1) from the panel air duct.
13. Remove the retaining bolts from the panel air duct.
14. Remove the panel air duct from the cross vehicle beam.
15. Remove the retaining bolts from the right air duct.
16. Remove the right air duct from the cross vehicle beam.
17. Remove the steering column. Refer to «Steering Column Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/steering-column-switches/#steering-wheel-steering-column) in Steering Wheel and Column.
18. Disconnect the left side fuse block from the cross vehicle beam.
19. Remove the passenger knee bolster bracket. Refer to «Knee Bolster Bracket Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
20. Position the body control module away from the cross vehicle beam.
21. Disconnect any ground wires, as necessary.
22. Remove the brake pedal. Refer to «Brake Pedal Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
23. Remove the 3 bolts from the brake pedal bracket to cross vehicle beam.
24. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
25. Remove the bolts from the HVAC module center support.
26. Remove the bracket from the HVAC module center support.
27. Reposition the vacuum harness.
28. Remove the bracket bolts from the HVAC module upper support.
29. Remove the bolts from the right and left side of the cross vehicle beam.
30. Remove the cross vehicle beam.
31. Disconnect the vacuum hoses from the HVAC control module.
32. Disconnect the electrical connectors from the HVAC control module.
33. Remove the evaporator drain elbow.
34. Remove the nuts which secure the HVAC control module to the dash.
35. Remove the HVAC control module: Pull the HVAC control module rearward to disengage the mounting studs from the dash panel. Position aside the dash insulator pad from the recirculation opening of the HVAC control module . Roll the HVAC control module downward and rearward to disconnect the heater core outlet cover from the rear floor air outlet duct. Remove the HVAC control module.
36. Remove and discard all of the seals (1,2,3) from the outer HVAC control module.

1. Install new seals (1,2,3) to the outer HVAC control module.
2. Install the HVAC control module into the vehicle: Align the heater core outlet cover to the rear floor air outlet duct. Roll the HVAC control module forward and upward and align the dash insulator pad to the recirculation opening of the HVAC control module. Align the mounting studs and the drain on the HVAC control module to seat against the dash panel.
3. Install the nuts which secure the HVAC control module to the dash. Tighten: Tighten the nuts to 10 N.m (89 lb in).
4. Install the evaporator drain elbow.
5. Connect the vacuum hoses to the HVAC control module.
6. Connect the electrical connectors to the HVAC control module.
7. Install the cross vehicle beam to the vehicle.
8. Install the bolts to the right and left side of the cross vehicle beam.
9. Tighten the bolts to the right and left side of the cross vehicle beam in sequence. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
10. Install the bracket bolts to the HVAC module upper support. Tighten: Tighten the bolts to 10 N.m (89 lb in).
11. Install the passenger knee bolster bracket. Refer to «Knee Bolster Bracket Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
12. Install the bracket to the HVAC module center support.
13. Install the bolts to the HVAC module center support.
14. Reposition the vacuum harness to the original position.
15. Tighten the bolts in sequence as shown. Tighten: Tighten the bolts to 10 N.m (89 lb in).
16. Reposition the IP wiring harness on to the cross vehicle beam and secure the retaining clips.
17. Install the 3 bolts through the brake pedal bracket to the cross vehicle beam. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
18. Install the brake pedal. Refer to «Brake Pedal Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
19. Connect all disconnected ground wires.
20. Install the body control module.
21. Install the left side fuse block to the cross vehicle beam.
22. Install the steering column. Refer to «Steering Column Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/steering-column-switches/#steering-wheel-steering-column) in Steering Wheel and Column.
23. Install the right air duct to the cross vehicle beam.
24. Install the right air duct bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
25. Install the panel air duct to the cross vehicle beam.
26. Install the panel air duct screw (1). Tighten: Tighten the screw to 1.8 N.m (16 lb in).
27. Install the panel air duct bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
28. Install the IP lower trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
29. Connect the inlet and outlet heater hose to the heater core.
30. Use J 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.
31. Install new O-rings seals on the evaporator tube and accumulator tube. Refer to «O-Ring Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) .
32. Connect the evaporator tube to the evaporator.
33. Connect the accumulator tube to the evaporator.
34. Install the accumulator tube to evaporator core block fitting bolt. Tighten: Tighten the screws to 16 N.m (12 lb ft).
35. Install the cross vehicle brace. Refer to «Brace Replacement - Cross Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
36. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
37. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-recovery-and-recharging) .
38. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
39. Leak test the fittings of the component using J 39400-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__special-tools) .

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__hvac-module-assembly-replacement) .
2. Remove all of the outer HVAC module assembly seals.
3. Remove the recirculation housing from the HVAC module assembly.
4. Release the retaining clip to the defroster actuator from the HVAC module assembly.
5. Remove the defroster actuator.
6. Remove the HVAC module assembly case upper screws.
7. Separate the HVAC module assembly case (1).
8. Remove the HVAC module assembly seal (2) from the lower module case (1).
9. Remove the evaporator core.
10. Remove the water core filter from the evaporator.

1. If replacing the evaporator, add refrigerant oil to the evaporator. Refer to «Refrigerant System Capacities»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__refrigerant-system-capacities) for system capacity information.
2. Install the water core filter to the evaporator.
3. Install a new side seal to the evaporator core.
4. Install a new upper seal to the evaporator core.
5. Install two new lower seals to the evaporator core.
6. Install the HVAC module assembly seal (2) to the lower module case (1).
7. Install the evaporator core into the HVAC module assembly lower case.
8. Align the guide (1) and attach the upper and lower HVAC module assembly case.
9. Install the HVAC module assembly upper screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
10. Install the defroster actuator to the HVAC module assembly.
11. Install the defroster actuator.
12. Install the recirculation housing to the HVAC module assembly.
13. Install the recirculation housing screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
14. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__hvac-module-assembly-replacement) .

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
2. Use J 38185 in order to position aside the heater hose inlet clamp.
3. Disconnect the heater inlet hose (3) from the inlet pipe.
4. Use J 38185 in order to position aside the heater core inlet hose clamp.
5. Disconnect the heater inlet hose from the heater core.
6. Remove the heater inlet hose.

1. Install the heater inlet hose.
2. Connect the heater inlet hose to the heater core. Use J 38185 in order to secure the heater core hose inlet clamp.
3. Connect the heater inlet hose (3) to the inlet pipe.
4. Use J 38185 in order to secure the heater hose inlet clamp.
5. Refill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L.
3. Use J 38185 in order to position aside the heater hose inlet clamp at the pipe adapter.
4. Disconnect the heater inlet hose from the pipe adapter.
5. Use J 38185 in order to position aside the heater core inlet hose clamp.
6. Disconnect the heater inlet hose from the heater core.
7. Remove the heater inlet hose from the support bracket.

1. Install the heater inlet hose to the support bracket.
2. Connect the heater inlet hose to the heater core.
3. Use J 38185 in order to secure the heater core hose inlet clamp.
4. Connect the heater inlet hose to the pipe adapter.
5. Use J 38185 in order to secure the heater hose inlet clamp.
6. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L.
7. Refill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
2. Use J 38185 in order to position aside the heater hose outlet clamp.
3. Disconnect the heater outlet hose (2) from the outlet pipe.
4. Use J 38185 in order to position aside the heater core outlet hose clamp.
5. Disconnect the heater outlet hose from the heater core.
6. Remove the heater outlet hose.

1. Install the heater outlet hose.
2. Connect the heater outlet hose to the heater core. Use J 38185 in order to secure the heater core hose outlet clamp.
3. Connect the heater outlet hose (2) to the outlet pipe.
4. Use J 38185 in order to secure the heater hose outlet clamp.
5. Refill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L.
3. Use J 38185 in order to position aside the heater hose outlet clamp at the pipe adapter.
4. Disconnect the heater outlet hose from the pipe adapter.
5. Use J 38185 in order to position aside the heater core outlet hose clamp.
6. Disconnect the heater outlet hose from the heater core.
7. Remove the heater outlet hose from the support bracket.

1. Install the heater outlet hose to the support bracket.
2. Connect the heater outlet hose to the heater core.
3. Use J 38185 in order to secure the heater core hose outlet clamp.
4. Connect the heater outlet hose to the pipe adapter.
5. Use J 38185 in order to secure the heater hose outlet clamp.
6. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L.
7. Refill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
2. Remove the air cleaner assembly.
3. Use J 38185 in order to position aside the heater hose inlet clamp.
4. Disconnect the inlet hose (3) from the heater inlet pipe.
5. Remove the heater inlet pipe mounting nut.
6. Remove the heater inlet pipe.

1. Install the heater inlet pipe.
2. Install the heater inlet pipe mounting nut. Tighten: Tighten the nut to 7 N.m (62 lb in).
3. Connect the inlet hose (3) to the heater inlet pipe.
4. Use J 38185 in order to position the heater hose inlet clamp.
5. Install the air cleaner assembly.
6. Refill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L.
3. Use J 38185 in order to position aside the heater hose clamp.
4. Disconnect the heater inlet hose from the heater pipe adapter.
5. Remove the heater pipe adapter mounting bolt.
6. Remove the heater pipe adapter.

1. Lubricate the O-ring seal with Dex-Cool antifreeze.
2. Install the heater pipe adapter
3. Install the heater inlet pipe adapter mounting bolt. Tighten: Tighten the bolt to 6 N.m (53 lb in).
4. Connect the inlet hose to the heater pipe adapter.
5. Use J 38185 in order to secure the heater core hose clamp.
6. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L.
7. Refill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L.
3. Use J 38185 in order to position aside the heater hose clamp.
4. Remove the heater outlet hose from the heater pipe adapter.
5. Remove the heater pipe adapter mounting bolt.
6. Remove the heater pipe adapter.

1. Lubricate the O-ring seal with Dex-Cool antifreeze.
2. Install the heater pipe adapter.
3. Install the heater outlet pipe adapter mounting bolt. Tighten: Tighten the bolt to 6 N.m (53 lb in).
4. Install the heater outlet hose to the pipe adapter.
5. Use J 38185 in order to secure the heater core hose clamp.
6. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L.
7. Refill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

1. Position the windshield wipers in the UP position, by keying the ignition OFF when the wiper reach the desired position.
2. Raise the hood.
3. Position aside the rear hood seal halfway to the center. Refer to «Seal Replacement - Hood Rear»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
4. Remove the right recirculation grill. Refer to «Air Inlet Grille Panel Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
5. Remove the passenger compartment air filter.

1. Install the passenger compartment air filter.
2. Install the recirculation grill. Refer to «Air Inlet Grille Panel Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
3. Install the rear hood seal. Refer to «Seal Replacement - Hood Rear»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
4. Close the hood.
5. Return the windshield wipers to the PARK position.

1. Remove the right side instrument panel insulator. Refer to «Closeout/Insulator Panel Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
2. Disconnect the electrical connector from the blower motor resistor.
3. Disconnect the electrical connector from the blower motor.
4. Loosen both screws to the forward blower motor resistor.
5. Remove the rear screw to the blower motor resistor.
6. Remove the blower motor resistor.

1. Install the blower motor resistor.
2. Install the rear screw to the blower motor resistor. Tighten: Tighten all screws to 1.5 N.m (13 lb in).
3. Connect the electrical connector to the blower motor.
4. Connect the electrical connector to the blower motor resistor.
5. Install the right side instrument panel insulator. Refer to «Closeout/Insulator Panel Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.

1. Remove the right side instrument panel insulator. Refer to «Closeout/Insulator Panel Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.
2. Release the instrument panel harness retainer and position the harness aside.
3. Disconnect the blower motor electrical connector.
4. Disconnect the blower motor cooling hose.
5. Remove the blower motor mounting screws.
6. Remove the blower motor.

1. Install the blower motor.
2. Install the blower motor screws. Tighten: Tighten the screws to 1.3 N.m (12 lb in).
3. Connect the blower motor cooling hose.
4. Connect the blower motor electrical connector.
5. Install the instrument panel harness into the harness retainer.
6. Install the right side instrument panel insulator. Refer to «Closeout/Insulator Panel Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages and Console.

1. Remove the I/P upper trim pad. Refer to «Trim Pad Replacement - Instrument Panel (I/P) Upper (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Trim Pad Replacement - Instrument Panel (I/P) Upper (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
2. For the left outlet only, remove the air outlet screw.
3. Disengage the air outlet retainers. Remove the air outlet.

1. Install the air outlet to the I/P upper trim pad and engage the air outlet retainers.
2. For the left outlet only, install the air outlet screw. Tighten: Tighten the screw to 2 N.m (18 lb in).
3. Install the I/P upper trim pad. Refer to «Trim Pad Replacement - Instrument Panel (I/P) Upper (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Trim Pad Replacement - Instrument Panel (I/P) Upper (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.

1. Remove the instrument panel (I/P) cluster trim plate. Refer to «Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
2. Use a small flat-bladed tool and pry the upper and lower retainers of the I/P air outlet deflector.
3. Lift out the deflector from the I/P cluster trim plate.

1. Position the air outlet deflector to the upper retainer tabs on the I/P cluster trim plate.
2. Position the deflector to the lower retainer tabs on the I/P cluster trim plate.
3. Install the deflector to the trim plate by pressing into place until the retainers are fully seated.
4. Inspect the deflector for proper operation.
5. Install the I/P cluster trim plate. Refer to «Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the IP lower trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
3. Remove the retaining screw (1) from the panel air duct.
4. Remove the retaining bolts from the panel air duct.
5. Remove the panel air duct from the cross vehicle beam.
6. Remove the steering column. Refer to «Steering Column Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/steering-column-switches/#steering-wheel-steering-column) in Steering Wheel and Column.
7. Disconnect the left side fuse block from the cross vehicle beam.
8. Remove the passenger knee bolster bracket. Refer to «Knee Bolster Bracket Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
9. Position the body control module away from the cross vehicle beam.
10. Remove the brake pedal. Refer to «Brake Pedal Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
11. Remove the three brake pedal brace bolts from the cross vehicle beam.
12. Disconnect any ground wires, as necessary.
13. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
14. Remove the bolts from the HVAC module center support.
15. Remove the bracket from the HVAC module center support.
16. Reposition the vacuum harness.
17. Remove the bracket bolts from the HVAC module upper support.
18. Remove the bolts from the right and left side of the cross vehicle beam.
19. Remove the cross vehicle beam.
20. Remove the defroster air duct retaining bolts.
21. Remove the defroster air duct from the cross vehicle beam.

1. Install the defroster air duct to the cross vehicle beam.
2. Install the defroster air duct bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the cross vehicle beam to the vehicle.
4. Install the bolts to the right and left side of the cross vehicle beam.
5. Tighten the bolts to the right and left side of the cross vehicle beam in sequence. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Install the bracket bolts to the HVAC module upper support. Tighten: Tighten the bolts to 10 N.m (89 lb in).
7. Install the passenger knee bolster bracket. Refer to «Knee Bolster Bracket Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
8. Install the bracket to the HVAC module center support.
9. Reposition the vacuum harness to the original position.
10. Install the bracket bolts to the HVAC module center support. Tighten: Tighten the bracket bolts in sequence to 10 N.m (89 lb in).
11. Reposition the IP wiring harness on to the cross vehicle beam and secure the retaining clips.
12. Connect all disconnected ground wires.
13. Install the three brake pedal brace bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
14. Install the brake pedal. Refer to «Brake Pedal Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
15. Reposition the body control module in place.
16. Install the left fuse block to the cross vehicle beam.
17. Install the steering column. Refer to «Steering Column Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/steering-column-switches/#steering-wheel-steering-column) in Steering Wheel and Column.
18. Install the panel air duct to the cross vehicle beam.
19. Install the panel air duct screw (1). Tighten: Tighten the screw to 1.8 N.m (16 lb in).
20. Instal the panel air duct bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
21. Install the lower trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
22. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.

1. Remove the I/P lower trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
2. Remove the retaining screw (1) from the panel air distribution duct.
3. Remove the retaining bolts from the panel air distribution duct.
4. Remove the panel air distribution duct from the cross vehicle beam.
5. Reposition the right I/P fuse junction block.
6. Remove the retaining bolts from the right air distribution duct.
7. Remove the right air distribution duct from the cross vehicle beam.

1. Install the right air distribution duct to the cross vehicle beam.
2. Install the right air distribution duct bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the right I/P fuse junction block.
4. Install the panel air distribution duct to the cross vehicle beam.
5. Install the panel air distribution duct screw (1). Tighten: Tighten the screw (1) to 1.8 N.m (16 lb in).
6. Install the panel air distribution duct bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
7. Install the I/P lower trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.

1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__hvac-module-assembly-replacement) .
2. Remove the screws retaining the right air temperature actuator.
3. Remove the right air temperature actuator.
4. Remove the screws retaining the left air temperature actuator.
5. Remove the left air temperature actuator.
6. Remove the air inlet housing retaining screws (1).
7. Remove the air inlet housing (2).
8. Remove the HVAC module upper mounting screws.
9. Release the retaining tab (1) and separate the upper and lower module halves.
10. Remove the HVAC module seal that is located between the upper and lower cases. Start to remove the HVAC module case seal (blower motor side of case) seal (2) from the lower module case at the position shown (1).
11. Carefully pull the air temperature doors apart in the center to remove the air temperature door from the HVAC module case. Remove the air temperature doors (1,2).

1. Install the air temperature doors (1,2). Carefully align the air temperature door into the HVAC module case.
2. Install the new case seal (2) into the HVAC module case (1).
3. Align and install the upper HVAC module case to the lower module case. Align and secure the retaining tab (1) on the upper module case to the retaining slot on the lower module case.
4. Install the HVAC module assembly upper mounting screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
5. Install the recirculation housing (2).
6. Install the recirculation housing retaining screws (1). Tighten: Tighten the screws to 1.5 N.m (13 lb in).
7. Position the right air temperature actuator, then align the slots in the electric actuator drive to the flats of the shaft.
8. Align the locating hole to the alignment pin on the HVAC module case.
9. Slide the actuator drive on the shaft. The actuator drive should set completely on the shaft and the mounting holes should be flush with the mounting screws on the HVAC module case.
10. Install the screws to the right air temperature actuator. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
11. Position the left air temperature actuator, then align the slots in the electric actuator drive to the flats of the shaft.
12. Align the locating hole to the alignment pin on the HVAC module case.
13. Slide the actuator drive on the shaft. The actuator drive should set completely on the shaft and the mounting holes should be flush with the mounting screws on the HVAC module case.
14. Install the screws to the left air temperature actuator. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
15. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__hvac-module-assembly-replacement) .

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__hvac-module-assembly-replacement) .
2. Remove the screws retaining the left air temperature actuator.
3. Remove the left air temperature actuator.
4. Remove the screws retaining the right air temperature actuator.
5. Remove the right air temperature actuator.
6. Remove the air inlet housing retaining screws (1).
7. Remove the air inlet housing (2).
8. Remove the HVAC module assembly upper mounting screws.
9. Release the retaining tab (1) securing the HVAC module assembly halves.
10. Separate the upper and lower module halves.
11. Remove the HVAC module seal that is located between the upper and lower cases. Start to remove the HVAC module case seal (blower motor side of case) seal (2) from the lower module case at the position shown (1).
12. Carefully pull the air temperature doors apart in the center to remove the air temperature door from the HVAC module case. Remove the air temperature doors (1,2).

1. Install the air temperature doors (1,2). Carefully align the air temperature door into the HVAC module case.
2. Install the new case seal (2) to the HVAC module assembly case (1).
3. Align and install the upper module case to the lower module case. Align and secure the retaining tab (1).
4. Install the HVAC module assembly upper mounting screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
5. Install the air inlet housing.
6. Install the air inlet housing retaining screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
7. Position the right air temperature actuator, then align the slots in the electric actuator drive to the flats of the shaft.
8. Align the locating hole to the alignment pin on the HVAC module case.
9. Slide the actuator drive on the shaft. The actuator drive should set completely on the shaft and the mounting holes should be flush with the mounting screws on the HVAC module case.
10. Install the screws to the right air temperature actuator. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
11. Position the left air temperature actuator, then align the slots in the electric actuator drive to the flats of the shaft.
12. Align the locating hole to the alignment pin on the HVAC module case.
13. Slide the actuator drive on the shaft. The actuator drive should set completely on the shaft and the mounting holes should be flush with the mounting screws on the HVAC module case.
14. Install the screws to the left air temperature actuator. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
15. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__hvac-module-assembly-replacement) .

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the IP lower trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
3. Remove the steering column. Refer to «Steering Column Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/steering-column-switches/#steering-wheel-steering-column) in Steering Wheel and Column.
4. Disconnect the left side fuse block from the cross vehicle beam.
5. Remove the retaining screw (1) from the panel air duct.
6. Remove the bolts from the panel air duct.
7. Remove the panel air duct from the cross vehicle beam.
8. Remove the retaining bolts from the right air duct.
9. Remove the right air duct from the cross vehicle beam.
10. Remove the passenger knee bolster bracket. Refer to «Knee Bolster Bracket Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
11. Position the body control module away from the cross vehicle beam.
12. Disconnect any ground wires, as necessary.
13. Remove the brake pedal. Refer to «Brake Pedal Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
14. Remove the 3 bolts from the brake pedal bracket to cross vehicle beam.
15. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
16. Remove the bolts from the HVAC module center support.
17. Remove the bracket from the HVAC module center support.
18. Reposition the vacuum harness.
19. Remove the bracket bolts from the HVAC module upper support.
20. Remove the bolts from the right and left side of the cross vehicle beam.
21. Remove the cross vehicle beam.
22. Disconnect the two vacuum lines from the defroster actuator (3).
23. Disconnect the orange vacuum line from the recirculation actuator and install a hand vacuum pump (2).
24. Remove the defroster actuator from its attachment to the HVAC module case.
25. Using the hand vacuum pump (2) open the recirculation actuator door.
26. Rotate the defroster actuator to the right and up into the opening between the back of the dash and the opening into the HVAC module. The opening which results when the recirculation actuator door is in the full open position.
27. Disconnect the defroster actuator from the defroster door arm.
28. Remove the retaining screws (1) to the air distribution case cover.
29. Remove the air distribution case cover (2).
30. Remove and discard the air distribution case seal.
31. Remove the linkage between the defroster door and the vent door on the left side of the HVAC module assembly.
32. Remove the defroster door (1).

1. Install the defroster door (1).
2. Connect the linkage between the defroster door and the vent door.
3. Install a new air distribution case seal.
4. Install the air distribution case cover (2).
5. Install the retaining screws (1) to the air distributor cover. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
6. Connect the orange vacuum line to a hand vacuum pump (2).
7. Using the hand vacuum pump (2) open the recirculation actuator door.
8. Rotate the defroster actuator to the right and up into the opening between the back of the dash and the opening into the HVAC module. The opening which results when the recirculation actuator door is in the full open position.
9. Connect the defroster actuator to the defroster door arm.
10. Position the defroster actuator on to the mounting slides of the HVAC module assembly.
11. Ensure that the lock tab locks the defroster actuator in place.
12. Connect the vacuum lines to the defroster actuator.
13. Connect the vacuum line to the recirculation actuator.
14. Install the cross vehicle beam to the vehicle.
15. Install the bolts to the right and left side of the cross vehicle beam.
16. Tighten the bolts to the right and left side of the cross vehicle beam in sequence. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
17. Install the bracket bolts to the HVAC module upper support. Tighten: Tighten the bolts to 10 N.m (89 lb in).
18. Install the passenger knee bolster bracket. Refer to «Knee Bolster Bracket Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
19. Install the bracket to the HVAC module center support.
20. Reposition the vacuum harness to the original position.
21. Install the bracket bolts to the HVAC module center support.
22. Tighten the bracket bolts in sequence as shown. Tighten: Tighten the bolts to 10 N.m (89 lb in).
23. Reposition the IP wiring harness to the cross vehicle beam and secure the retaining clips.
24. Install the 3 bolts through the brake pedal bracket to the cross vehicle beam. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
25. Install the brake pedal. Refer to «Brake Pedal Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
26. Connect all disconnected ground wires.
27. Reposition the body control module in place.
28. Install the fuse blocks to the cross vehicle beam.
29. Install the right air duct to the cross vehicle beam.
30. Install the right air duct bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
31. Install the panel air duct to the cross vehicle beam.
32. Install the panel air duct screw (1). Tighten: Tighten the bolts to 1.8 N.m (16 lb in).
33. Install the panel air duct bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
34. Install the steering column. Refer to «Steering Column Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/steering-column-switches/#steering-wheel-steering-column) in Steering Wheel and Column.
35. Install the lower trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
36. Connect the battery negative cable.

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the IP lower trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
3. Remove the steering column. Refer to «Steering Column Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/steering-column-switches/#steering-wheel-steering-column) in Steering Wheel and Column.
4. Disconnect the left side fuse block from the cross vehicle beam.
5. Remove the retaining screw (1) from the panel air duct.
6. Remove the bolts from the panel air duct.
7. Remove the panel air duct from the cross vehicle beam.
8. Remove the retaining bolts from the right air duct.
9. Remove the right air duct from the cross vehicle beam.
10. Remove the passenger knee bolster bracket. Refer to «Knee Bolster Bracket Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
11. Position the body control module away from the cross vehicle beam.
12. Disconnect any ground wires, as necessary.
13. Remove the brake pedal. Refer to «Brake Pedal Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
14. Remove the 3 bolts from the brake pedal bracket to cross vehicle beam.
15. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
16. Remove the bolts from the HVAC module center support.
17. Remove the bracket from the HVAC module center support.
18. Reposition the vacuum harness.
19. Remove the bracket bolts from the HVAC module upper support.
20. Remove the bolts from the right and left side of the cross vehicle beam.
21. Remove the cross vehicle beam.
22. Disconnect the vacuum lines from the mode actuator.
23. Lift the lock tab up (1) to remove the actuator.
24. Remove the mode actuator off the slides of the HVAC module assembly.
25. Disconnect the actuator pushrod from the mode door lever and remove the actuator.
26. Remove the retaining screws (1) to the air distribution case cover.
27. Remove the air distribution case cover (2).
28. Remove and discard the air distribution case seal.
29. Remove the mode door (2).

1. Install the mode door (2).
2. Install a new air distribution case seal.
3. Install the air distribution case cover (2).
4. Install the retaining screws (1) to the air distributor cover. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
5. Connect the mode actuator pushrod to the mode door lever.
6. Position the mode actuator on to the mounting slides of the HVAC module assembly.
7. Ensure that the lock tab locks the defroster actuator in place.
8. Connect the vacuum lines to the mode actuator.
9. Install the cross vehicle beam to the vehicle.
10. Install the bolts to the right and left side of the cross vehicle beam.
11. Tighten the bolts to the right and left side of the cross vehicle beam in sequence. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
12. Install the bracket bolts to the HVAC module upper support. Tighten: Tighten the bolts to 10 N.m (89 lb in).
13. Install the passenger knee bolster bracket. Refer to «Knee Bolster Bracket Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
14. Install the bracket to the HVAC module center support.
15. Reposition the vacuum harness to the original position.
16. Install the bracket bolts to the HVAC module center support.
17. Tighten the bracket bolts in sequence as shown. Tighten: Tighten the bolts 10 N.m (89 lb in).
18. Reposition the IP wiring harness on to the cross vehicle beam and secure the retaining clips.
19. Install the 3 bolts through the brake pedal bracket to the cross vehicle beam. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
20. Install the brake pedal. Refer to «Brake Pedal Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
21. Connect all disconnected ground wires.
22. Reposition the body control module in place.
23. Install the left side fuse block to the cross vehicle beam.
24. Install the right air duct to the cross vehicle beam.
25. Install the right air duct bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
26. Install the panel air duct to the cross vehicle beam.
27. Install the panel air duct screw (1). Tighten: Tighten the bolts to 1.8 N.m (16 lb in).
28. Install the panel air duct bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
29. Install the steering column. Refer to «Steering Column Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/steering-column-switches/#steering-wheel-steering-column) in Steering Wheel and Column.
30. Install the IP lower trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) or «Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo)»(/chevrolet/monte-carlo/vi-1999-2007/remont/gauges-instrument-panels/#instrument-panel-gages-and-console) in Instrument Panel, Gages, and Console.
31. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.

1. Remove the vacuum tank. Refer to «Vacuum Tank Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/manual-hvac-system/#hvac-systems-manual) in HVAC System - Manual.
2. Remove the floor carpet. Refer to «Carpet Replacement - Front»(/chevrolet/monte-carlo/vi-1999-2007/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
3. Remove the rear floor air outlet duct (1) from the holes in the floor reinforcement.
4. Disconnect the rear floor air outlet duct from the heater core outlet cover.
5. Remove the bolts from the vacuum harness bracket and position bracket aside.
6. Remove the heater outlet cover screws.
7. Remove the heater outlet cover.
8. Disconnect the defroster/vent door link at the vent door on the left side of the HVAC module assembly.
9. Remove the heater core cover screws.
10. Remove the heater core cover.
11. Remove the vent door (1) from the HVAC module assembly.

1. Install the vent door (1) to the HVAC module assembly.
2. Install the heater core cover.
3. Install the heater core cover screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
4. Install the heater core outlet cover.
5. Install the screws to the heater core outlet cover. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
6. Install the HVAC vacuum harness bracket.
7. Install the screws to the HVAC vacuum harness bracket. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
8. Connect the defroster/vent door link at the vent door on the left side of the HVAC module assembly.
9. Connect the rear floor air outlet duct to the heater core outlet cover.
10. Install the rear floor air outlet duct (1) to the holes in the floor reinforcement.
11. Install the floor carpet. Refer to «Carpet Replacement - Front»(/chevrolet/monte-carlo/vi-1999-2007/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
12. Install the vacuum tank. Refer to «Vacuum Tank Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/manual-hvac-system/#hvac-systems-manual) in HVAC System - Manual.

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__hvac-module-assembly-replacement) .
2. Lift the recirculation actuator lock tab and slide the recirculation actuator off the mounting bracket.
3. Disconnect the vacuum actuator plunger rod from the recirculation lever and remove the recirculation actuator.
4. Remove the recirculation housing retaining screws (1).
5. Remove the recirculation housing (2) from the HVAC module assembly.
6. Remove the recirculation door (1) from the recirculation housing (2).

1. Install the recirculation door.
2. Align the retaining tabs and install the recirculation housing (2) to the HVAC module assembly.
3. Install the recirculation housing screws. Tighten: Tighten the recirculation housing screws to 1.5 N.m (13 lb in).
4. Connect the recirculation actuator plunger rod to the recirculation door lever, then extend the plunger.
5. Install the recirculation actuator on to the mounting bracket of the HVAC assembly. IMPORTANT: Inspect the recirculation actuator pushrod for binding on the recirculation door lever.
6. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic__hvac-module-assembly-replacement) .

J 38185 Hose Clamp Pliers

1. Remove the fuel injector sight shield, if equipped with 3.8L. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L.
2. Drain the coolant. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
3. Use J 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
4. Disconnect the inlet and outlet heater hose from the heater core.
5. Remove the vacuum tank. Refer to «Vacuum Tank Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/manual-hvac-system/#hvac-systems-manual) in HVAC System - Manual.
6. Remove the floor carpet. Refer to «Carpet Replacement - Front»(/chevrolet/monte-carlo/vi-1999-2007/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
7. Remove the rear floor air outlet duct from the holes in the floor reinforcement.
8. Disconnect the rear floor air outlet duct from the heater core outlet cover.
9. Remove the bolts from the vacuum harness bracket and position bracket aside.
10. Remove the heater outlet cover screws.
11. Remove the heater outlet cover.
12. Remove the heater core cover screws.
13. Remove the heater core cover.
14. Remove and discard the seals (1,2) from the heater core cover.
15. Remove the caulk (3) from the heater core outlet cover.
16. Remove and discard the outer seal (5) from the heater core.
17. Remove the heater core pipe retainer clamp screw (2) from the heater core retainer clamp.
18. Remove the heater core retaining clamp screw (1) from the heater core.
19. Remove the retaining clamp from the heater core.
20. Remove the heater core from the HVAC lower case.
21. Remove the heater core pipe retainer clamp from the heater core pipes.
22. Remove and discard the heater core lower seal (4) from the HVAC case.
23. Remove and discard the heater core center seal (3) from the HVAC case.
24. Remove and discard the heater core upper seal (2) from the HVAC lower case.
25. Remove and discard the heater core side seals (1) from the HVAC lower case.

1. Install new heater core side seals (1) to the HVAC lower case.
2. Install a new heater core upper seal (2) to the HVAC lower case.
3. Install a new heater core center seal (3) to the HVAC case.
4. Install a new heater core lower seal (4) to the HVAC case.
5. Install the heater core retaining clamp to the heater core pipes.
6. Install the heater core in to the HVAC lower case.
7. Install the screw (2) to the heater core retaining clamp. Tighten: Tighten the clamp screw to 1.5 N.m (13 lb in).
8. Install the heater core mounting clip with a screw (1). Tighten: Tighten the screw to 1.5 N.m (13 lb in).
9. Install heater core outer seal (5) to the heater core.
10. Install new seals (1,2) to the heater core cover.
11. Install the caulk (3) on to the heater core outlet cover.
12. Install the heater core cover.
13. Install the heater core cover screws. Tighten: Tighten the cover screws to 1.5 N.m (13 lb in).
14. Install the heater core outlet cover.
15. Install the screws to the heater core outlet cover. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
16. Install the HVAC vacuum harness bracket.
17. Install the screws to the HVAC vacuum harness bracket. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
18. Connect the rear floor air outlet duct to the heater core outlet cover.
19. Install the rear floor air outlet duct to the holes in the floor reinforcement.
20. Install the floor carpet. Refer to «Carpet Replacement - Front»(/chevrolet/monte-carlo/vi-1999-2007/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
21. Install the vacuum tank. Refer to «Vacuum Tank Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/manual-hvac-system/#hvac-systems-manual) in HVAC System - Manual.
22. Connect the inlet and outlet heater hose to the heater core.
23. Use J 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.
24. Refill the coolant. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
25. Install the fuel injector sight shield, if equipped with 3.8L. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L.

1. Remove the floor carpet. Refer to «Carpet Replacement - Front»(/chevrolet/monte-carlo/vi-1999-2007/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
2. Remove the rear floor air outlet duct (1) from the holes in the floor reinforcement.
3. Disconnect the lower heater duct from the heater core outlet cover.
4. Remove the lower heater duct.

1. Install the lower heat duct.
2. Connect the lower heater duct to the heater core outlet cover.
3. Position the rear floor air outlet duct (1) into the holes in the floor reinforcement.
4. Install the floor carpet. Refer to «Carpet Replacement - Front»(/chevrolet/monte-carlo/vi-1999-2007/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.

Special Tools

Special Tools Illustration Tool Number/ Description J 5403 Internal Snap Ring Pliers J 6083 External Snap Ring Pliers J 8092 Driver Handle - 3/4 in - 10 J 8433 Two Jaw Puller J 8433-1 Puller Bar J 8433-3 Forcing Screw J 9398 Rotor Bearing Remover J 9481-A Bearing Installer J 21352-A Support Block J 26549-E Orifice Tube Remover J 33013-B Hub and Drive Plate Remover/Installer J 33017 Pulley and Bearing Installer J 33019 Pulley Bearing Staking Tool J 33020 Pulley Puller J 33022 6-Shaft nut Socket - 13mm - 6 pt J 33023-A Puller Pilot J 33024 Clutch Coil Installer Adapter J 33025 Clutch Coil Puller Legs J 33027-A A/C Clutch Hub Holder J 34992 Compressor Holding Fixture J 38185 Hose Clamp Pliers J 39037 Charge Valve Octagon Socket J 39400-A Halogen Leak Detector J 39893 Pressure Test Adapter J 41447 R134A A/C Tracer Dye - Box of 24 J 41552 Compressor Pulley Puller J 41790 Compressor Holding Fixture J 42136 A/C Lip Seal Remover J 42220 Universal 12V Leak Detection Lamp 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 46297 A/C Dye Injector Kit J 46297 12 Replacement Dye Cartridges

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

See also:
• Diagnostic System Check - HVAC Systems - Manual
• Air Delivery Description and Operation
• Air Temperature Description and Operation
• Moving Parts and Hot Surfaces Caution
• Cooling System Description and Operation
• Cooling Fan Inoperative
• Engine Fails To Reach Normal Operating Temperature
• Air Delivery Improper
• Drive Belt Excessive Wear Diagnosis
• Drive Belt Excessive Wear Diagnosis
• Drive Belt Tensioner Diagnosis
• Drive Belt Tensioner Diagnosis
• Vibration Analysis - Engine
• Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala)
• Loss of Coolant
• Oil Leak Diagnosis
• Oil Leak Diagnosis
• DIAGNOSIS - 4T65-E
• Power Steering Fluid Leaks
• Fastener Notice
• Lifting and Jacking the Vehicle
• Splash Shield Replacement - Engine - Right
• Vacuum Brake Booster Replacement (3.4L)
• Brake Pressure Modulator Valve (BPMV) Bracket Replacement
• Battery Disconnect Caution
• Battery Negative Cable Disconnect/Connect Procedure
• Steering Column Replacement
• Carpet Replacement - Front
• Special Tools
• Refrigerant Recovery and Recharging
• Leak Testing
• Air Conditioning (A/C) Diagnostics - Pressure Zone A
• Air Conditioning (A/C) System Performance Test
• Accumulator Replacement
• Flushing
• Refrigerant System Capacities
• Heating Performance Diagnostic
• Clutch Rotor and/or Bearing Replacement (V-5 Conventional Mount)
• Compressor Clutch Plate and Hub Assembly Removal (V5 - Direct Mount)
• Clutch Rotor and/or Bearing Removal (V5 - Direct Mount)
• Compressor Leak Testing (V5 - Conventional Mount)
• Compressor Leak Testing (CVC7)
• Clutch Rotor and/or Bearing Install (V5 - Direct Mount)
• Compressor Clutch Plate/Hub Assembly Install (V5 - Direct Mount)
• HVAC Module Assembly Replacement