Heating, Ventilation and Air Conditioning: Removal & Installation Chevrolet Silverado 2500

Compressor Replacement (L35 W/Harrison)

Tools Required: J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the drive belt.
3. Remove the A/C compressor hose assembly bolt from the A/C compressor.
4. Remove the A/C compressor hose assembly from the A/C compressor.
5. Disconnect the electrical connectors.
6. Remove the A/C compressor mounting bolts.
7. Remove the A/C compressor from the bracket.
8. If replacing the A/C compressor, drain and measure as much of the oil as possible from the removed compressor. 8.1. Drain the oil from both the suction and discharge ports of the removed A/C compressor into a clean container. 8.2. Remove the A/C compressor crankcase oil drain plug and drain the crankcase oil into the same container. 8.3. Measure and record the amount of oil drained from the removed A/C compressor. This measurement will be used during installation of the replacement A/C compressor. 8.4. Properly discard the used PAG oil.

Installation Procedure

1. Add the proper amount of PAG oil to the compressor crankcase. Refer to «Refrigerant System Capacities»(ref-175819-S17851943202005042700000) .
2. Install the A/C compressor drain plug. Tighten the drain plug to 20 N.m (15 lb ft).
3. Install the compressor into the bracket.
4. Install the compressor bolts. Tighten the bolts to 50 N.m (37 lb ft).
5. Install the A/C compressor hose to the compressor using new sealing washers.
6. Install the A/C compressor hose bolt to the A/C compressor. Tighten the bolt to 34 N.m (25 lb ft).
7. Connect the electrical connections.
8. Install the drive belt.
9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
10. Leak test the fittings of the component using the J 39400-A.

Compressor Replacement (LB7 w/Denso)

Tools Required J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Install a ratchet into the belt tensioner adapter opening.
3. Rotate the belt tensioner counterclockwise in order to relieve the tension on the belt.
4. Remove the belt from the A/C compressor.
5. Slowly release the tension on the belt tensioner.
6. Remove the discharge hose bolt from the A/C compressor.
7. Remove the discharge hose from the A/C compressor.
8. Remove the suction hose bolt from the A/C compressor.
9. Remove the suction hose from the A/C compressor.
10. Discard the sealing washers. Cap all of the openings.
11. Disconnect the electrical connections.
12. Remove the A/C compressor mounting bolts.
13. If replacing the A/C compressor, drain and measure as much of the oil as possible from the removed compressor. 13.1. Drain the oil from both the suction and discharge ports of the removed A/C compressor into a clean container. 13.2. Measure and record the amount of oil drained from the removed A/C compressor. This measurement will be used during installation of the replacement A/C compressor. 13.3. Properly discard the used PAG oil.

1. Add the proper amount of PAG oil to the compressor crankcase. Refer to «Refrigerant System Capacities»(ref-175819-S17851943202005042700000) .
2. Install the A/C compressor drain plug. Tighten the drain plug to 20 N.m (15 lb ft).
3. Install the A/C compressor.
4. Install the A/C compressor mounting bolts. Tighten the bolts to 50 N.m (37 lb ft).
5. Connect the electrical connection.
6. Install the A/C discharge hose to the compressor using new sealing washers.
7. Instal the A/C discharge hose bolt to the A/C compressor. Tighten the bolt to 16 N.m (12 lb ft).
8. Install the A/C suction hose to the compressor using new sealing washers.
9. Install the A/C suction hose bolt to the A/C compressor. Tighten the bolt to 16 N.m (12 lb ft).
10. Install the drive belt.
11. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
12. Leak test the fittings of the component using the J 39400-A.

Compressor Replacement (LB7 w/Harrison)

Tools Required: J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the drive belt.
3. Remove the compressor hose assembly bolt from the A/C compressor.
4. Remove the compressor hose assembly from the A/C compressor.
5. Discard the sealing washers. Cap all of the openings.
6. Disconnect the electrical connections.
7. Remove the A/C compressor mounting bolts.
8. If replacing the A/C compressor, drain and measure as much of the oil as possible from the removed compressor. 8.1. Drain the oil from both the suction and discharge ports of the removed A/C compressor into a clean container. 8.1. Remove the A/C compressor crankcase oil drain plug and drain the crankcase oil into the same container. 8.3. Measure and record the amount of oil drained from the removed A/C compressor. This measurement will be used during installation of the replacement A/C compressor. 8.4. Properly discard the used PAG oil.

1. Add the proper amount of PAG oil to the compressor crankcase. Refer to «Refrigerant System Capacities»(ref-175819-S17851943202005042700000) .
2. Install the A/C compressor.
3. Install the A/C compressor mounting bolts. Tighten the bolts to 50 N.m (37 lb ft).
4. Connect the electrical connection.
5. Install the refrigerant hose to the compressor using new sealing washers. Refer to «Compressor Hose Assembly Replacement (L35 w/Harrison)»(ref-175819-S03599596062005042700000) , «Compressor Hose Assembly Replacement (L18 w/Harrison)»(ref-175819-S01331750502005042700000) or «Compressor Hose Assembly Replacement (LB7 w/Harrison)»(ref-175819-S31648386642005042700000) .
6. Install the drive belt.
7. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
8. Leak test the fittings of the component using the J 39400-A .

Compressor Replacement (LR4, LM7, LQ4, L18 w/Denso)

Tools Required: J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
3. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
4. Remove the A/C belt from the A/C compressor.
5. Slowly release the tension on the A/C belt tensioner.
6. Remove the right front tire and wheel assembly.
7. Remove the wheel house panel from the vehicle.
8. Remove the discharge hose bolt from the A/C compressor.
9. Remove the discharge hose from the A/C compressor.
10. Remove the suction hose bolt from the A/C compressor.
11. Remove the suction hose from the A/C compressor.
12. Discard the sealing washers. Cap all of the openings.
13. Disconnect the electrical connections.
14. Remove the A/C compressor mounting bolts. The lower right bolt (3) will stay with the compressor due to a lack of clearance.
15. Remove the A/C compressor (2) from the bracket (1).
16. If replacing the A/C compressor, drain and measure as much of the oil as possible from the removed compressor. 16.1. Drain the oil from both the suction and discharge ports of the removed A/C compressor into a clean container. 16.1. Measure and record the amount of oil drained from the removed A/C compressor. This measurement will be used during installation of the replacement A/C compressor. 16.3. Properly discard the used PAG oil.

1. Add the proper amount of PAG oil to the compressor crankcase. Refer to «Refrigerant System Capacities»(ref-175819-S17851943202005042700000) .
2. Install the A/C compressor (2) to the bracket (1) through the fender well. Insert the mounting bolt (3) into the lower right mounting boss before installing the A/C compressor.
3. Install the A/C compressor to the bracket. Insert the mounting bolt into the lower right mount before installing the A/C compressor.
4. Install the A/C compressor mounting bolts. Tighten the bolts to 50 N.m (37 lb ft).
5. Connect the electrical connector to the A/C compressor.
6. Install the A/C discharge hose to the compressor using new sealing washers.
7. Install the A/C discharge hose bolt to the A/C compressor. Tighten the bolt to 16 N.m (12 lb ft).
8. Install the A/C suction hose to the compressor using new sealing washers.
9. Install the A/C suction hose bolt to the A/C compressor. Tighten the bolt to 16 N.m (12 lb ft).
10. Install the wheel house panel to the vehicle.
11. Install the right front tire and wheel assembly.
12. Install the A/C drive belt.
13. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
14. Leak test the fittings of the component using the J 39400-A .

Compressor Replacement (L18 w/Harrison)

Tools Required: J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the air conditioning (A/C) drive belt.
3. Raise and support the vehicle.
4. Remove the right front tire and wheel assembly.
5. Remove the right wheel house panel.
6. Remove the compressor hose assembly bolt from the A/C compressor.
7. Remove the compressor hose assembly from the A/C compressor.
8. Discard the sealing washers. Cap all of the openings.
9. Disconnect the electrical connections.
10. Remove the 3 A/C compressor mounting bolts. The lower right bolt will stay with the compressor due to a lack of clearance.
11. Remove the A/C compressor from the bracket through the fender well.
12. If replacing the A/C compressor, drain and measure as much of the oil as possible from the removed compressor. 12.1. Drain the oil from both the suction and discharge ports of the removed A/C compressor into a clean container. 12.2. Remove the A/C compressor crankcase oil drain plug and drain the crankcase oil into the same container. 12.3. Measure and record the amount of oil drained from the removed A/C compressor. This measurement will be used during installation of the replacement A/C compressor. Properly discard the used PAG oil.

1. Add the proper amount of PAG oil to the compressor crankcase. Refer to «Refrigerant System Capacities»(ref-175819-S17851943202005042700000) .
2. Install the A/C compressor drain plug. Tighten the drain plug to 20 N.m (15 lb ft).
3. Install the A/C compressor to the mounting bracket. Important: Insert the mounting bolt into the lower right mounting bracket before installing the A/C compressor.
4. Install the 3 A/C compressor mounting bolts. Tighten the bolts to 50 N.m (37 lb ft).
5. Connect the electrical connection.
6. Install the A/C compressor hose assembly to the compressor using new sealing washers.
7. Install the A/C compressor hose assembly bolt to the A/C compressor. Tighten the bolt to 34 N.m (25 lb ft).
8. Install the right wheel house panel.
9. Install the right front tire and wheel assembly.
10. Lower the vehicle.
11. Install the A/C drive belt.
12. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
13. Leak test the fittings of the component using the J 39400-A .

Clutch Rotor And/Or Bearing Removal

Tools Required

1. J 6083 External Snap Ring Pliers
2. J 33023-A Puller Pilot
3. J 41552 Compressor Pulley Puller
4. J 29886 Driver Handle
5. J 9398-A Bearing Remover

Scheme 35

Scheme 36

Scheme 37

1. Remove the clutch plate and hub assembly. Refer to «Compressor Clutch Plate/Hub Assembly Replacement (HD6/HT6/HU6)»(ref-175819-S24080760842005042700000) .
2. Use the J 6083 in order to remove the following components: The pulley rotor (1) The bearing assembly retaining ring (2)
3. Install the J 33023-A to the front head.
4. Install the J 41552 down into the inner circle of slots (1) in the rotor.
5. Turn the J 41552 clockwise in the slots in the rotor.
6. Perform the following steps in order to remove the pulley rotor and bearing assembly: 6.1. Hold the J 41552 in position. 6.2. Tighten the puller screw against the puller guide. 6.3. Remove the pulley rotor and bearing assembly.
7. Use the following procedure in order to properly support the rotor hub during the bearing removal in order to prevent pulley rotor damage: 7.1. Remove the forcing screw from the J 41552. 7.2. Verify that the puller tangs still engage in the rotor slots. 7.3. Invert the assembly onto a solid flat surface or blocks. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged.
8. Use the J 9398-A and the J 29886 in order to drive the bearing out of the rotor hub.

Scheme 38

1. Remove the clutch plate retaining bolt (1).
2. Remove the clutch plate assembly.
3. Remove the clutch hub/bearing snap ring.
4. Remove the clutch hub/bearing assembly.
5. Remove the clutch coil connector bracket retaining screw.
6. Remove the clutch coil snap ring.
7. Remove the clutch coil assembly.

Compressor Clutch Coil Removal (HT6/HD6/HU6)

Tools Required

1. J 6083 External Snap Ring Pliers
2. J 33023-A Puller Pilot
3. J 41552 Compressor Pulley Puller
4. J 8433-1 Puller Bar
5. J 33025 Clutch Coil Puller Legs
6. J 8433-3 Forcing Screw

Scheme 39

Scheme 40

Scheme 41

1. Remove the clutch plate and hub assembly. Refer to «Compressor Clutch Plate/Hub Assembly Replacement (HD6/HT6/HU6)»(ref-175819-S24080760842005042700000) .
2. Use the J 6083 in order to remove the following components: The pulley rotor (1) The bearing assembly retaining ring (2)
3. Install the J 33023-A to the front head.
4. Install the J 41552 down into the inner circle of slots (1) in the rotor.
5. Turn the J 41552 clockwise in the slots in the rotor.
6. Perform the following steps in order to remove the pulley rotor and bearing assembly: 6.1. Hold the J 41552 in position. 6.2. Tighten the puller screw against the puller guide. 6.3. Remove the pulley rotor and bearing assembly.
7. Mark the clutch coil terminal location (1) on the compressor front head. Refer to «Clutch Rotor And/Or Bearing Removal»(ref-175819-S15827293942005042700000) .
8. Install the J 33023-A on the front head of the compressor.
9. Install the J 8433-1 and the J 33025 .
10. Tighten the J 8433-3 against the puller pilot in order to remove the clutch coil (2).

Compressor Pressure Relief Valve Removal (HT6/HD6/HU6)

Tools Required: J 34992 Compressor Holding Fixture

Scheme 42

1. Install the compressor onto the J 34992.
2. Remove the pressure relief valve (5) from the rear head of the compressor.

Compressor Control Switches Removal (HT6/HD6/HU6)

Tools Required

1. J 43600 ACR 2000 Air Conditioning Service Center
2. J 5403 Snap Ring Pliers
3. J 9553-01 O-Ring Remover

Scheme 43

1. Recover the refrigerant using the J 43600.
2. Disconnect the electrical connector from the switch (2) in the rear head of the compressor.
3. Remove the switch retaining ring using the J 5403.
4. Remove the switch (2) from the compressor.
5. Remove the old O-ring seal from the switch cavity using the J 9553-01.
6. Inspect the switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the components as necessary.

Compressor Clutch Plate/Hub Assembly Replacement (HD6/HT6/HU6)

Tools Required

Scheme 44

1. J 34992 Compressor Holding Fixture
2. J 33013-B Hub and Drive Plate Remover/Installer

1. Remove the A/C compressor. Refer to «Compressor Replacement (L35 W/Harrison)»(ref-175819-S24772361372005042700000) , «Compressor Replacement (LB7 w/Denso)»(ref-175819-S18669133342005042700000) , «Compressor Replacement (LB7 w/Harrison)»(ref-175819-S05366009552005042700000) , «Compressor Replacement (LR4, LM7, LQ4, L18 w/Denso)»(ref-175819-S36944855002005042700000) or «Compressor Replacement (L18 w/Harrison)»(ref-175819-S02410485672005042700000) .
2. Clamp the J 34992 in a vise.
3. Use thumb screws in order to attach the compressor to the holding fixture. NOTE: Do not drive or pound on the clutch hub or shaft. Internal damage to the compressor may result. The forcing tip on the J 33013-B remover/installer center screw must be flat or the end of the shaft/axial plate assembly will be damaged.
4. Ensure that the center screw forces the tip to thrust against the end of the shaft.
5. Thread the J 33013-B into the hub.
6. While holding the body of J 33013-B of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly (1).
7. Remove the shaft key. Retain the shaft key for reassembly.

Scheme 45

1. Install the shaft key (4) into the hub key groove. Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway (3). The shaft key curves slightly in order to provide an interference fit in the hub key groove.
2. Clean the following components: The clutch plate The clutch rotor (2)
3. Align the shaft key (4) with the shaft keyway (3).
4. Place the clutch plate and the hub assembly (1) onto the compressor shaft.
5. Remove the forcing tip on the J 33013-B .
6. Reverse the body direction on the center screw.
7. Install the J 33013-B with the bearing.
8. Back off the body of the J 33013-B as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft.
9. Hold the center screw with a wrench.
10. Tighten the hex portion of the J 33013-B body in order to press the hub onto the shaft.
11. Tighten the body several turns.
12. Remove the installer. Ensure that the shaft key remains in place in the keyway.
13. Install the clutch plate and hub assembly to the final position. Ensure that the air gap (2) between frictional surfaces of the clutch plate and clutch rotor measures within 0.50-0.76 mm (0.020-0.030 in).
14. Remove the J 33013-B .
15. Verify proper positioning of the shaft key. Ensure that the shaft key is even with or slightly above the clutch hub.
16. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate.
17. Install the A/C compressor. Refer to «Compressor Replacement (L35 W/Harrison)»(ref-175819-S24772361372005042700000) , «Compressor Replacement (LB7 w/Denso)»(ref-175819-S18669133342005042700000) , «Compressor Replacement (LB7 w/Harrison)»(ref-175819-S05366009552005042700000) , «Compressor Replacement (LR4, LM7, LQ4, L18 w/Denso)»(ref-175819-S36944855002005042700000) or «Compressor Replacement (L18 w/Harrison)»(ref-175819-S02410485672005042700000) .

Scheme 46

1. Remove the A/C compressor. Refer to «Compressor Replacement (L35 W/Harrison)»(ref-175819-S24772361372005042700000) , «Compressor Replacement (LB7 w/Denso)»(ref-175819-S18669133342005042700000) , «Compressor Replacement (LB7 w/Harrison)»(ref-175819-S05366009552005042700000) , «Compressor Replacement (LR4, LM7, LQ4, L18 w/Denso)»(ref-175819-S36944855002005042700000) or «Compressor Replacement (L18 w/Harrison)»(ref-175819-S02410485672005042700000) .
2. Remove the A/C belt tensioner bolts.
3. Remove the A/C belt tensioner.
4. Remove the A/C compressor bracket mounting bolts.
5. Remove the A/C compressor bracket.

1. Install the A/C compressor bracket.
2. Install the A/C compressor bracket mounting bolts. Tighten the bolts to 50 N.m (37 lb ft).
3. Install the A/C belt tensioner.
4. Install the A/C belt tensioner bolts. Tighten the bolts to 50 N.m (37 lb ft).
5. Install the A/C compressor. Refer to «Compressor Replacement (L35 W/Harrison)»(ref-175819-S24772361372005042700000) , «Compressor Replacement (LB7 w/Denso)»(ref-175819-S18669133342005042700000) , «Compressor Replacement (LB7 w/Harrison)»(ref-175819-S05366009552005042700000) , «Compressor Replacement (LR4, LM7, LQ4, L18 w/Denso)»(ref-175819-S36944855002005042700000) or «Compressor Replacement (L18 w/Harrison)»(ref-175819-S02410485672005042700000) .

Scheme 47

1. Remove the seal washer from the A/C refrigerant component. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.
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. Important: DO NOT reuse sealing washer.
4. Discard the sealing washer.

Important: Flat washer type seals do not require lubrication.

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. Important: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component.
5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.

Important: Take the following measures when installing sealing washers

Scheme 48

1. Keep dirt and foreign material from the sealing surfaces of the washers, the hose block, and the compressor ports. Clean all of the sealing surfaces with a lint-free rag.
2. Do not reuse sealing washers.
3. The sealing washers do not need oiling prior to assembly.

1. Install the sealing washer onto the pilots of the suction/discharge block fitting. The washers must bottom against the surface of the block fitting.
2. Install the hose block to the compressor. Ensure that the sealing washers are seated within the compressor machined surfaces.
3. Hold the block in place. Tighten the bolt to 34 N.m (25 lb in).

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. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.
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. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system.
4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. Important: DO NOT reuse O-ring seals.
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.

Compressor Hose Assembly Replacement (L35 w/Harrison)

Tools Required

J 39400-A Halogen Leak Detector

Scheme 49

Scheme 50

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the compressor hose assembly mounting bolt from the A/C compressor.
3. Remove the compressor hose assembly from the A/C compressor.
4. Remove the compressor hose assembly nut from the accumulator.
5. Remove the compressor hose assembly from the accumulator.
6. Remove the upper radiator baffle.
7. Remove the compressor hose assembly nut at the condenser.
8. Remove the compressor hose assembly from the condenser.
9. Disconnect the electrical connector from the A/C recirculation switch.
10. Remove the A/C compressor hose assembly.
11. Discard all of the used sealing washers. Cap the system openings.

1. Install the A/C compressor hose assembly.
2. Connect the electrical connector to the A/C recirculation switch.
3. Install the A/C compressor hose assembly to the condenser.
4. Install the A/C compressor hose assembly nut to the condenser. Tighten the nut to 16 N.m (12 lb ft).
5. Install the upper radiator baffle.
6. Install the A/C compressor hose assembly to the accumulator using new sealing washers. Refer to «Compressor Mounting Bracket Replacement»(ref-175819-S16188159052005042700000) .
7. Install the nut to the accumulator. Tighten the nut to 16 N.m (12 lb ft).
8. Install the bolt to the A/C compressor hose assembly. Tighten the bolt to 34 N.m (25 lb ft).
9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
10. Leak test the fittings of the component using the J 39400-A .

Compressor Hose Assembly Replacement (L18 w/Harrison)

Tools Required: J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the A/C compressor hose mounting bolt from the A/C compressor.
3. Remove the A/C compressor hose from the A/C compressor.
4. Remove the A/C compressor hose nut from the accumulator.
5. Remove the A/C compressor hose from the accumulator.
6. Remove the upper radiator baffle.
7. Remove the A/C compressor hose nut from the condenser.
8. Remove the A/C compressor hose from the condenser.
9. Disconnect the A/C recirculation switch electrical connector from the A/C compressor hose assembly.
10. Remove the A/C compressor hose assembly from the vehicle.
11. Discard all of the used sealing washers. Cap the system openings.

1. Install the A/C compressor hose assembly to the vehicle.
2. Connect the A/C recirculation switch electrical connector to the A/C compressor hose assembly.
3. Install the A/C compressor hose assembly to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-175819-S26890151452005042700000) .
4. Install the A/C compressor hose nut to the condenser. Tighten the nut to 16 N.m (12 lb ft).
5. Install the upper radiator baffle.
6. Connect the A/C compressor hose assembly to the accumulator using new sealing washers.
7. Install the nut at the accumulator. Tighten the nut to 16 N.m (12 lb ft).
8. Install the A/C compressor hose assembly mounting bolt. Tighten the nut to 34 N.m (25 lb ft).
9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
10. Leak test the fittings of the component using the J 39400-A .

Compressor Hose Assembly Replacement (LB7 w/Harrison)

Tools Required: J 39400-A Halogen Leak Detector

Scheme 51

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the A/C compressor hose assembly mounting bolt (2) from the A/C compressor (3). Discard the bolt.
3. Remove the A/C compressor hose assembly (1) from the compressor (3).
4. Remove the nut from the accumulator. Discard the nut.
5. Remove the A/C compressor hose from the accumulator.
6. Remove the upper radiator baffle.
7. Remove the nut from the condenser. Discard the nut.
8. Remove the A/C compressor hose from the condenser.
9. Disconnect the A/C recirculation switch from the A/C compressor hose assembly.
10. Remove the A/C compressor hose assembly from the vehicle.
11. Discard all of the used sealing washers. Cap the system openings.

1. Install the A/C compressor hose assembly to the vehicle.
2. Connect the A/C recirculation switch to the A/C compressor hose assembly.
3. Install the A/C compressor hose to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-175819-S26890151452005042700000) .
4. Install the NEW nut to the condenser. Tighten the nut to 16 N.m (12 lb ft).
5. Install the upper radiator baffle.
6. Install the A/C compressor hose assembly to the accumulator using new sealing washers.
7. Install the NEW nut to the accumulator. Tighten the nut to 16 N.m (12 lb ft).
8. Install the A/C compressor hose assembly to the accumulator to A/C compressor using new sealing washers.
9. Install the NEW A/C compressor hose assembly mounting bolt (2). Tighten the bolt to 34 N.m (25 lb ft).
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
11. Leak test the fittings of the component using the J 39400-A .

Discharge Hose Replacement (LR4, LM7, LQ4 & L18 w/Denso)

Tools Required: J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the discharge hose mounting bolt (2) from the A/C compressor.
3. Remove the discharge hose (1) from the A/C compressor.
4. Remove the upper radiator baffle.
5. Remove the discharge hose nut from the condenser.
6. Remove the discharge hose from the condenser.
7. Disconnect the electrical connector from the A/C recirculation switch.
8. Remove the discharge hose from the vehicle.
9. Discard all of the used sealing washers. Cap the system openings.

1. Install the discharge hose (1) to the vehicle.
2. Connect the electrical connector to the A/C recirculation switch.
3. Install the discharge hose to the condenser using new sealing washers.
4. Install the discharge hose nut to the condenser. Tighten the nut to 16 N.m (12 lb ft).
5. Install the upper air baffle.
6. Install the discharge hose (1) to the A/C compressor using new sealing washers.
7. Install the discharge hose mounting bolt. Tighten the bolt to 16 N.m (12 lb ft).
8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
9. Leak test the fittings of the component using the J 39400-A .

Discharge Hose Replacement (LB7 w/Denso)

Tools Required: J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the discharge hose mounting bolt (2) from the A/C compressor. Discard the bolt.
3. Remove the discharge hose (5) from the A/C compressor.
4. Remove the upper radiator air baffle.
5. Remove the discharge hose nut from the condenser. Discard the nut.
6. Remove the discharge hose from the condenser.
7. Disconnect the A/C recirculation switch from the discharge hose.
8. Remove the discharge hose from the vehicle.
9. Discard all of the used sealing washers. Cap the system openings.

1. Install the discharge hose to the vehicle.
2. Connect the A/C recirculation switch to the discharge hose.
3. Install the discharge hose to the condenser using new sealing washers.
4. Install the NEW discharge hose nut to the condenser. Tighten the nut to 16 N.m (12 lb ft).
5. Install the upper radiator air baffle.
6. Install the discharge hose (5) to the compressor using new sealing washers.
7. Install the NEW discharge hose mounting bolt (2) to the A/C compressor. Tighten the bolt to 16 N.m (12 lb ft).
8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
9. Leak test the fittings of the component using the J 39400-A .

Suction Hose Replacement (LB7 w/Denso)

Tools Required: J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the suction hose mounting bolt (3) from the A/C compressor. Discard the bolt.
3. Remove the suction hose (1) from the compressor.
4. Remove the suction hose nut from the accumulator. Discard the nut.
5. Remove the suction hose from the accumulator.
6. Remove the suction hose from the vehicle.
7. Discard all of the used sealing washers. Cap the system openings.

1. Install the suction hose to the vehicle using new sealing washers.
2. Install the suction hose to the accumulator.
3. Install the NEW suction hose nut to the accumulator. Tighten the nut to 16 N.m (12 lb ft).
4. Install the suction hose to the compressor (1).
5. Install the NEW suction hose mounting bolt (3). Tighten the bolt to 16 N.m (12 lb ft).
6. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
7. Leak test the fittings of the component using the J 39400-A .

Suction Hose Replacement (LR4, LM7, LQ4 & L18 w/Denso)

Tools Required: J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the suction hose mounting bolt from the A/C compressor.
3. Remove the suction hose (2) from the A/C compressor.
4. Remove the suction hose nut from the accumulator.
5. Remove the suction hose from the accumulator.
6. Remove the suction hose assembly from the vehicle.
7. Discard all of the used sealing washers. Cap the system openings.

1. Install the suction hose to the vehicle.
2. Install the suction hose to the accumulator using new sealing washers.
3. Install the suction hose nut to the accumulator. Tighten the nut to 16 N.m (12 lb ft).
4. Install the suction hose (2) to the compressor using new sealing washers.
5. Install the suction hose mounting bolt to the A/C compressor. Tighten the bolt to 16 N.m (12 lb ft).
6. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
7. Leak test the fittings of the component using the J 39400-A .

Evaporator Tube Replacement

Tools Required: J 39400-A Halogen Leak Detector

Scheme 52

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the evaporator tube nut from the evaporator.
3. Remove the evaporator tube from the evaporator.
4. Remove the right park/turn signal lamp.
5. Remove the grille from the vehicle.
6. Remove the evaporator tube nut from the condenser.
7. Remove the evaporator tube from the condenser.
8. Remove the evaporator tube from the vehicle.
9. Discard all of the used sealing washers. Cap all of the open connections.

1. Install the evaporator tube to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-175819-S26890151452005042700000) .
2. Install the evaporator tube nut to the condenser. Tighten the nut to 16 N.m (12 lb ft).
3. Install the grille to the vehicle.
4. Install the right park/turn signal lamp.
5. Install the evaporator tube to the evaporator.
6. Install the evaporator tube nut to the evaporator. Tighten the nut to 16 N.m (12 lb ft).
7. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
8. Leak test the fittings of the components using the J 39400-A .

Air Conditioning (A/C) Refrigerant Filter Installation

Tools Required: J 39400-A Halogen Leak Detector

Important: The A/C Refrigerant filter, ACDelco P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing.

Scheme 53

1. Remove the air cleaner.
2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location.
3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. Important: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs.
4. Using a tubing cutter, cut the marked section of the evaporator tube (2).
5. Remove the burrs from the evaporator tube (2).
6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). Important: DO NOT install the O-rings (2) in this step.
7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves.
8. Install the ferrules (3) with the small end toward the nut (4).
9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator.
10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten the nuts to 15 N.m (11 lb ft).
11. Remove the nuts (4) from the A/C refrigerant filter (1).
12. Coat the O-rings (2) with 525 viscosity refrigerant oil.
13. Install the O-rings (2) to the evaporator tube halves.
14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten the nuts to 15 N.m (11 lb ft).
15. Evacuate and recharge the system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
16. Leak test the fittings of the component using the J 39400-A .
17. Install the air cleaner.

Air Conditioning (A/C) Refrigerant Filter Replacement

Tools Required: J 39400-A Halogen Leak Detector

Scheme 54

1. Recover the refrigerant from the system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the air cleaner. Important: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove.
3. Remove the nuts (4) from the A/C refrigerant filter (1).
4. Remove the A/C refrigerant filter (3) from the evaporator tube (2).

1. Coat the O-rings (2) with 525 viscosity refrigerant oil.
2. Install the O-rings (2) to the evaporator tube.
3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator.
4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten the nuts to 15 N.m (11 lb ft).
5. Recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A .
7. Install the air cleaner.

Expansion (Orifice) Tube Replacement

Tools Required

1. J 26549-E Orifice Tube Remover
2. J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Loosen the nut from the evaporator tube fitting.
3. Use the J 26549-E in order to remove the orifice tube (1) from the evaporator tube (2).
4. Cap or plug the open line.

1. Uncap or unplug the evaporator tube.
2. Lubricate the new O-ring using new 525 viscosity refrigerant oil.
3. Install the new O-ring seal.
4. Install the orifice tube (1) to the evaporator tube (2). 4.1. Coat the O-ring seal with 525 viscosity refrigerant oil. 4.2. Insert the short screen end of the new orifice (1) into the evaporator tube.
5. Connect the evaporator tube at the fitting. Tighten the fitting to 25 N.m (18 lb ft).
6. Evacuate and recharge the system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
7. Leak test the fittings of the repaired component using J 39400-A .

Suction Screen Installation

Tools Required: J 44551 Suction Screen Kit

Important: Suction screens are intended to be installed in the suction hose after a major compressor failure.

The suction screens are available in 3 different sizes.

1. Insert the J 44551-6 sizing tool into the suction hose to select the correct size suction screen.
2. Insert the suction screen into the compressor end of the suction hose.
3. Install the correct mandrel to the J 44551-5.
4. Install the J 44551-5 screen installation tool over the end of the suction hose and the suction screen. Important: Correct placement of the J 44551-5 is critical.
5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting.
6. Remove the J 44551-1 suction screen tool from the suction hose. Important: After a major compressor failure an A/C refrigerant filter should also be installed.
7. Install an A/C refrigerant filter. Refer to «Air Conditioning (A/C) Refrigerant Filter Installation»(ref-175819-S25976747012005042700000) .
8. Install the J 44551-1 Suction Screen Notification label.

Suction Screen Replacement

Tools Required

1. J 42220 Universal Leak Detection Lamp
2. J 44551 Suction Screen Kit

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the A/C compressor hose assembly bolt.
3. Separate the A/C compressor hose assembly from the A/C compressor. Important: The suction screens are available in 3 different sizes.
4. Select the proper size removal tool from the J 44551 .
5. Remove the suction screen using the J 44551-31 suction screen removal tool. Thread the forcing screw into the suction screen. Tighten the nut on the forcing screw to remove the suction screen.

1. Insert the J 44551-6 sizing tool into the suction hose to select the correct size suction screen.
2. Insert the suction screen into the suction hose.
3. Install the J 44551-3 mandrel to the J 44551-5.
4. Install the J 44551-5 suction screen installation tool over the end of the suction hose and the suction screen. Important: Correct placement of the J 44551-5 is critical.
5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose.
6. Remove the J 44551-5 suction screen tool from the suction hose.
7. Replace the seal washers. Refer to «Sealing Washer Replacement»(ref-175819-S26890151452005042700000) .
8. Install the A/C compressor hose assembly to the A/C compressor.
9. Install the A/C compressor hose assembly bolt. Tighten the bolt to 34 N.m (25 lb ft).
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
11. Leak test the fittings of the component using the J 42220 .

Scheme 55

1. Remove the cover from the underhood convenience center (1).
2. Remove the compressor relay (2).

1. Install the compressor relay (2).
2. Install the cover to the underhood convenience center (1).

Air Conditioning (A/C) High Pressure Switch Replacement

Tools Required

1. J 5403 Snap Ring Pliers
2. J 9553-01 O-Ring Remover
3. J 39400-A Halogen Leak Detector

1. Recover the refrigerant the system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Clean the control A/C high pressure switch area before removing the snap ring.
3. Disconnect the electrical connector from the A/C high pressure switch (2).
4. Remove the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403 .
5. Remove the A/C high pressure switch (2) from the compressor.
6. Remove the old O-ring seal from the A/C high pressure switch cavity using the J 9553-01 .
7. Inspect the A/C high pressure switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the components as necessary.

Important: If you reinstall an existing control switch in the compressor, use a new O-ring and a new retainer ring. An O-ring and a retainer ring is included in a new switch kit.

1. Lubricate the new O-ring using new 525 viscosity refrigerant oil.
2. Install the new O-ring into the groove in the switch cavity.
3. Lubricate the control switch housing using new 525 viscosity refrigerant oil.
4. Install the switch (2) into the switch cavity until the switch bottoms in the cavity.
5. Install the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403 . Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the snap ring is properly seated in the switch cavity retaining groove.
6. Evacuate and recharge the system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
7. Leak test the fittings of the components using the J 39400-A .

Scheme 56

1. Disconnect the electrical connector from the A/C low pressure switch.
2. Remove the A/C low pressure switch from the accumulator.
3. Remove the O-ring and discard.

1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil.
2. Install the NEW O-ring seal to the switch.
3. Install the A/C low pressure switch to the accumulator. Tighten the switch to 6 N.m (53 lb in).
4. Connect the electrical connector to the A/C low pressure switch.
5. Leak test the fittings of the components using the J 39400-A .

Scheme 57

1. Raise and support the vehicle.
2. Disconnect the electrical connector from the A/C high pressure recirculation switch.
3. Remove the A/C high pressure recirculation switch from the evaporator tube.

1. Install the A/C high pressure recirculation switch. Tighten the switch to 6 N.m (53 lb in).
2. Connect the electrical connector to the A/C high pressure recirculation switch.
3. Leak test the fittings of the components using the J 39400-A.
4. Lower the vehicle.

Condenser Replacement

Tools Required: J 39400-A Halogen Leak Detector

1. Remove the radiator.
2. For vehicles equipped with the LB7 engine, remove the charged air cooler.
3. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
4. Remove the compressor discharge hose assembly bolt from the condenser.
5. Disconnect the compressor discharge hose assembly from the condenser.
6. Remove the evaporator tube nut from the condenser.
7. Disconnect the evaporator tube from the condenser.
8. Remove the insulator retainer bolts and the upper insulator retainers.
9. Remove the condenser from the vehicle.

1. Install the condenser to the vehicle.
2. Install the upper insulator retainers and the insulator retainer bolts. Tighten the bolts to 2.4 N.m (21 lb in).
3. Connect the evaporator tube to the condenser using new sealing washers.
4. Install the evaporator tube nut to the condenser. Tighten the evaporator tube nut to 16 N.m (12 lb ft).
5. Connect the compressor discharge hose to the condenser using new sealing washers.
6. Install the compressor discharge hose nut to the condenser. Tighten the compressor discharge hose nut to 16 N.m (12 lb ft).
7. For vehicles equipped with the LB7 engine, install the charged air cooler.
8. Install the radiator.
9. Evacuate and recharge the system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
10. Leak test the fittings of the component using the J 39400-A .

Accumulator Replacement

Tools Required: J 39400-A Halogen Leak Detector

Scheme 58

1. Recover the refrigerant. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
2. Remove the evaporator tube nut from the evaporator.
3. Remove the evaporator tube from the evaporator.
4. Remove the nut from the evaporator tube (3).
5. Disconnect the electrical connector from the A/C low pressure switch.
6. Remove the compressor hose nut from the accumulator.
7. Remove the compressor hose from the accumulator.
8. Remove the nut (2) from the evaporator fitting.
9. Remove the accumulator bracket nut (4) from the retaining stud.
10. Remove the accumulator (3).
11. Remove the retaining bracket bolt (5).
12. Remove the retaining bracket (6) from the accumulator.
13. Remove and discard the O-ring seals.

1. Install new O-ring seals. Refer to «O-Ring Replacement»(ref-175819-S34492049542005042700000) .
2. Install the retaining bracket (6) to the accumulator.
3. Install the retaining bracket bolt (5). Tighten the bolt to 10 N.m (89 lb in).
4. Install the accumulator (3).
5. Install the accumulator bracket nut (4). Tighten the nut to 9 N.m (80 lb in).
6. Install the nut (2) to the evaporator fitting. Tighten the nut to 16 N.m (12 lb ft).
7. Install the compressor hose to the accumulator.
8. Install the compressor hose nut to the accumulator. Tighten the nut to 16 N.m (12 lb ft).
9. Connect the electrical connector to the A/C low pressure switch.
10. Install the nut to the evaporator tube (3). Tighten the nut to 25 N.m (18 lb ft).
11. Install the evaporator tube to the evaporator.
12. Install the evaporator tube nut to the evaporator. Tighten the nut to 16 N.m (12 lb ft).
13. Evacuate and recharge the system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
14. Leak test the fittings of the component using the J 39400-A .

Scheme 59

1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .
2. Remove the heater/vent module screws.
3. Separate the heater/vent module.
4. Remove the evaporator core from the heater/vent module.

1. Install the evaporator core to the heater/vent module.
2. Install the heater/vent module halves.
3. Install the heater/vent module screws. Tighten the screws to 1.6 N.m (14 lb in).
4. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .
5. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery & Recharging»(ref-175819-S28225795812005042700000) .
6. Leak test the fittings of the component using the J 39400-A .

Heater Hose Replacement - Inlet (L18)

Tools Required: J 43181 Quick Connect Connector Removal Tool

Scheme 60

1. Drain the cooling system.
2. Remove the air intake tube.
3. Remove the heater and surge tank hose from the mounting clip.
4. Using the J 43181 disconnect the heater hose from the heater core inlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
5. Remove the inlet heater hose (1) from the engine coolant inlet fitting.
6. Remove the inlet heater hose.

1. Install the inlet heater hose.
2. Install the inlet heater hose (1) to the engine coolant inlet fitting.
3. Connect the heater and surge tank hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
4. Install the heater and surge tank hose to the mounting clip.
5. Install the air intake tube.
6. Fill the cooling system.

Heater Hose Replacement - Inlet (LB7)

Tools Required: J 43181 Quick Connect Connector Removal Tool

1. Drain the cooling system.
2. Remove the air intake tube.
3. Remove the heater and surge tank hose from the mounting clip.
4. Using the J 43181 disconnect the heater hose from the heater core inlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
5. Reposition the inlet heater hose clamp from the engine coolant outlet.
6. Remove the inlet heater hose (1) from the engine coolant outlet.
7. Remove the auxiliary inlet heater hose if equipped.
8. Remove the inlet heater hose.

1. Install the heater hose.
2. Connect the auxiliary inlet heater hose if equipped.
3. Install the inlet heater hose (1) to the engine coolant outlet.
4. Reposition the inlet heater hose clamp to the engine coolant outlet.
5. Connect the heater and surge tank hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
6. Install the heater and surge tank hose to the mounting clip.
7. Install the air intake tube.
8. Fill the cooling system.

Heater Hose Replacement - Inlet (L35)

Tools Required: J 43181 Quick Connect Connector Removal Tool

Scheme 61

1. Drain the cooling system.
2. Remove the air intake tube.
3. Using the J 43181 disconnect the heater hose from the heater core inlet. 3.1. Install the J 43181 to the heater core pipe. 3.2. Close the tool around the heater core pipe. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
4. Reposition the inlet heater hose clamp from the engine.
5. Remove the inlet heater hose from the engine.
6. Remove the inlet heater hose mounting bolt.
7. Remove the inlet heater hose from the engine.
8. Remove the inlet heater hose.

1. Install the inlet heater hose.
2. Install the inlet heater hose to the engine.
3. Reposition the inlet heater hose clamp to the engine.
4. Install the inlet heater hose mounting bolt. Tighten the bolt to 25 N.m (18 lb ft).
5. Install the inlet heater hose to the engine.
6. Connect the heater hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
7. Install the air intake tube.
8. Fill the cooling system.

Heater Hose Replacement - Inlet (LR4, LM7 & LQ4)

Tools Required: J 43181 Quick Connect Connector Removal Tool

Scheme 62

1. Drain the cooling system.
2. Remove the air intake tube.
3. Remove the heater and surge tank hose from the mounting clip.
4. Using the J 43181 disconnect the heater hose from the heater core inlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
5. Remove the inlet heater hose from the engine.
6. Remove the inlet heater hose.

1. Install the inlet heater hose.
2. Install the inlet heater hose to the engine.
3. Connect the heater and surge tank hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
4. Install the heater and surge tank hose to the mounting clip.
5. Install the air intake tube.
6. Fill the cooling system.

Heater Hose Replacement - Outlet (L18)

Tools Required: J 43181 Quick Connect Connector Removal Tool

1. Drain the cooling system.
2. Remove the air intake tube.
3. Remove the heater and surge tank hose from the mounting clip.
4. Using the J 43181 disconnect the heater hoses from the heater core outlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
5. Remove the outlet heater hose from the radiator.
6. Remove the outlet heater hose (1).

1. Install the outlet heater hose (1).
2. Install the outlet heater hose to the radiator.
3. Connect the heater and surge tank hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
4. Install the heater and surge tank hose to the mounting clip.
5. Install the air intake tube.
6. Fill the cooling system.

Heater Hose Replacement - Outlet (LB7)

Tools Required: J 43181 Quick Connect Connector Removal Tool

1. Drain the cooling system.
2. Remove the air intake tube.
3. Remove the heater and surge tank hose from the mounting clip.
4. Using the J 43181 disconnect the heater hose from the heater core outlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
5. Remove the outlet heater hose nut (2) from the engine. Discard the nut.
6. Remove the outlet heater hose bolt (3) from the engine. Discard the nut.
7. Remove the auxiliary outlet heater hose if equipped.
8. Remove the outlet heater hose from the outlet pipe assembly.
9. Remove the outlet heater hose.

1. Install the outlet heater hose.
2. Install the outlet heater hose to the outlet pipe assembly.
3. Install the auxiliary outlet heater hose if equipped.
4. Install the NEW outlet heater hose nut (2) and bolt (3) to the engine. Tighten the nut and bolt to 25 N.m (18 lb ft).
5. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
6. Install the outlet heater hose to the mounting clip.
7. Install the air intake tube.
8. Fill the cooling system.

Heater Hose Replacement - Outlet (L35)

Tools Required: J 43181 Quick Connect Connector Removal Tool

Scheme 63

1. Drain the cooling system.
2. Remove the air intake tube.
3. Using the J 43181 disconnect the heater hose from the heater core outlet. 3.1. Install the J 43181 to the heater core pipe. 3.2. Close the tool around the heater core pipe. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
4. Remove the outlet heater hose from the engine.
5. Remove the outlet heater hose mounting bolt.
6. Remove the outlet heater hose from the engine.
7. Remove the outlet heater hose.

1. Install the heater hose.
2. Install the outlet heater hose to the engine.
3. Install the outlet heater hose mounting bolt. Tighten the bolt to 25 N.m (18 lb ft).
4. Connect the heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
5. Install the air intake tube.
6. Fill the cooling system.

Heater Hose Replacement - Outlet (LR4, LM7, LQ4)

Tools Required: J 43181 Quick Connect Connector Removal Tool

Scheme 64

1. Drain the cooling system.
2. Remove the air intake tube.
3. Remove the heater and surge tank hose from the mounting clip.
4. Using the J 43181 disconnect the heater hose from the heater core outlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
5. Remove the outlet heater hose from the engine.
6. Remove the outlet heater hose.

1. Install the outlet heater hose.
2. Install the outlet heater hose to the engine.
3. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
4. Install the heater and surge tank hose to the mounting clip.
5. Install the air intake tube.
6. Fill the cooling system.

Scheme 65

1. If equipped, remove the IP sound insulator.
2. Remove the filter access door screw.
3. Remove the filter access door (1) from the HVAC module.
4. Remove the passenger compartment air filter (2).

1. Install the passenger compartment air filter (2).
2. Install the filter access door (1) to the HVAC module.
3. Install the filter access door screw. Tighten the screw to 1.6 N.m (14 lb in).
4. If equipped, install the IP sound insulator.

Scheme 66

Scheme 67

1. If equipped, remove the IP sound insulator.
2. Disconnect the electrical connection from the blower motor.
3. Disconnect the electrical connection from the blower motor resistor.
4. Remove the blower motor resistor retaining screws.
5. Remove the blower motor resistor.

1. Install the blower motor resistor.
2. Install the blower motor resistor retaining screws. Tighten the screws to 1.6 N.m (14 lb in).
3. Connect the electrical connection to the blower motor resistor.
4. Connect the electrical connection to the blower motor.
5. If equipped, install the IP sound insulator.

Scheme 68

Scheme 69

1. If equipped, remove the sound insulator panel.
2. Remove the blower motor insulating cover screws.
3. Disconnect the electrical connector from the blower motor.
4. Remove the blower motor insulating cover.
5. Pull the retaining tab down while turning the blower motor counter-clockwise in order to disengage the blower motor from the heater/ventilation module.
6. Remove the blower motor.

1. Install the blower motor.
2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place.
3. Install the blower motor insulating cover.
4. Connect the electrical connector to the blower motor.
5. Install the blower motor insulating cover screws. Tighten the screws to 1.6 N.m (14 lb in).
6. If equipped, install the sound insulator panel.

Scheme 70

1. Remove the IP carrier.
2. Remove the air distribution duct retaining screws.
3. Remove the air distribution duct.

1. Install the air distribution duct.
2. Install the air distribution duct retaining screws.
3. Tighten the screws. Tighten the screws to 1.6 N.m (14 lb in).
4. Install the IP carrier.

1. Remove the IP carrier.
2. Remove the air tube from the side window outlet duct.
3. Remove the side window air outlet duct.

1. Install the side window air outlet duct.
2. Install the air tube to the side window outlet duct.
3. Install the IP carrier.

Scheme 71

1. Remove the instrument panel (I/P) bezel.
2. Remove the air deflector housing from the I/P by prying it out.
3. Disconnect the electrical connectors.
4. Remove the air deflector screws.
5. Remove the air deflector from the housing.

1. Install the air deflector to the housing.
2. Install the retaining screws. Tighten the screws to 1.6 N.m (14 lb in).
3. Connect the electrical connectors.
4. Install the air deflector assembly to the I/P.
5. Install the I/P bezel.

Scheme 72

1. Remove the instrument panel (I/P) bezel.
2. Remove the I/P trim panel.
3. Remove the deflector mounting screws.
4. Remove the deflector from the I/P.

1. Install the deflector to the I/P.
2. Install the deflector mounting screws. Tighten the screw to 1.6 N.m (14 lb in).
3. Install the I/P trim panel.
4. Install the instrument panel (I/P) bezel.

Scheme 73

1. Use a flat blade tool in order to remove the deflector from the instrument panel.
2. Remove the deflector.

1. Align the deflector into the opening in the instrument panel.
2. Push the deflector into the instrument panel until the deflector snaps into place.

Scheme 74

1. Remove the heater/ventilation module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .
2. Remove the floor air outlet screws.
3. Remove the floor air outlet (1).

1. Install the floor air outlet.
2. Install the floor air outlet screws (1). Tighten the screws to 1.6 N.m (14 lb in).
3. Install the heater/ventilation module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .

Scheme 75

1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .
2. Remove the heater/vent module screws.
3. Separate the heater/vent module halves.
4. Remove the air temperature door (8).

1. Install the air temperature door (8).
2. Assemble the heater/vent module halves.
3. Install the heater/vent module screws. Tighten the screws to 1.6 N.m (14 lb in).
4. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .

Scheme 76

1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .
2. Remove the heater/vent module screws.
3. Separate the heater/vent module.
4. Remove the mode actuator screws.
5. Remove the mode actuator (3).
6. Remove the mode actuator cam assembly (4).
7. Remove the defroster door lever (2).
8. Remove the defroster door (1).

1. Install the defroster door (1).
2. Install the defroster door lever (2).
3. Install the mode actuator cam assembly (4).
4. Install the mode actuator (3).
5. Install the mode actuator screws.
6. Install the mode actuator screws. Tighten the screws to 1.6 N.m (14 lb in).
7. Install the heater/vent module halves.
8. Install the screws to the heater/vent module. Tighten the screws to 1.6 N.m (14 lb in).
9. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .

Scheme 77

Scheme 78

Scheme 79

1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .
2. Disconnect the recirculation actuator electrical connection (1).
3. Remove the recirculation actuator mounting screws.
4. Remove the recirculation actuator.
5. Remove the recirculation door.

1. Install the recirculation door.
2. Install the recirculation actuator.
3. Install the recirculation actuator mounting screws. Tighten the screws to 1.9 N.m (17 lb in).
4. Connect the recirculation actuator electrical connection (1).
5. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .

Scheme 80

1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .
2. Remove the heater/vent module screws.
3. Separate the heater/vent module.
4. Remove the mode actuator (3).
5. Remove the mode actuator cam assembly (4).
6. Remove the heater door cam assembly (5).
7. Remove the heater door (6).

1. Remove the heater door (6).
2. Install the heater door cam assembly (5).
3. Install the mode actuator cam assembly (4).
4. Install the mode actuator (3).
5. Install the heater/vent module halves.
6. Install the heater/vent module screws. Tighten the screws to 1.6 N.m (14 lb in).
7. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .

Scheme 81

Scheme 82

1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .
2. Remove the heater core cover screws.
3. Remove the heater core cover.
4. Remove the heater core.

1. Install the heater core.
2. Install the heater core cover.
3. Install heater core cover screws. Tighten the screws to 1.6 N.m (14 lb in).
4. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-175819-S36620210262005042700000) .

Scheme 83

Scheme 84

1. Drain the engine coolant.
2. Reposition the inlet heater hose clamp from the heater core.
3. Remove the inlet heater hose from the heater core.
4. Reposition the outlet heater hose clamp from the heater core.
5. Remove the outlet heater hose from the heater core.
6. Remove the accumulator. Refer to «Accumulator Replacement»(ref-175819-S42392221472005042700000) .
7. Remove the IP carrier.
8. Remove the heater/vent module drain hose.
9. Disconnect the electrical harnesses and the ground connections.
10. Remove the heater/vent module mounting nuts and the screws.
11. Remove the heater/vent module assembly from the vehicle.

1. Install the heater/vent module assembly to the vehicle.
2. Install the heater/vent module mounting nuts. Tighten the nuts to 9 N.m (80 lb in).
3. Install the heater/vent module mounting screws. Tighten the screws to 4 N.m (35 lb in).
4. Connect the electrical harnesses and the ground connections.
5. Install the heater/vent module drain hose.
6. Install the IP carrier.
7. Install the accumulator.
8. Install the outlet heater hose to the heater core.
9. Reposition the outlet heater hose clamp to the heater core.
10. Install the inlet heater hose to the heater core.
11. Reposition the inlet heater hose clamp to the heater core.
12. Fill the engine coolant.
13. Leak test the fitting of the repaired component using J 39400-A .

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90