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Home/Chevrolet/Uplander/Chevrolet Uplander I (2004-2008)/Repair manual/Automatic HVAC System/Heating, Ventilation and Air Conditioning: Removal & Instal…
Contents Wiring diagrams Section: Automatic HVAC System All sections

Heating, Ventilation and Air Conditioning: Removal & Installation Chevrolet Uplander I

Automatic HVAC System 1 illustration ~10053 words

Removal Procedure

  1. Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Disconnect the A/C compressor electrical connector.
  3. If equipped with a C60 compressor, remove the discharge line (3) to compressor nut (4).
  4. Remove the suction line (5) to compressor nut (4).
  5. Remove the discharge (3) and suction (5) lines from the compressor.
  6. Remove and discard the sealing washers (2).
  7. If equipped with a C69 compressor, remove the discharge line (5) to compressor nut (4).
  8. Remove the suction line (2) to compressor nut (1).
  9. Remove the discharge (5) and suction (5) lines from the compressor.
  10. Remove and discard the sealing washers (3).
  11. Release the drive belt tensioner.
  12. Remove the drive belt from the generator pulley.
  13. Remove the drive belt from the A/C compressor.
  14. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
  15. Remove the air deflector bolts and deflector.
  16. Remove the passenger side engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
  17. Remove the A/C compressor bolts.
  18. Remove the A/C compressor.

Installation Procedure

IMPORTANTReplacement A/C compressors are partially precharged with polyalkylene glycol (PAG) oil. Refer to Refrigerant System Capacities .
  1. If replacing the A/C compressor, balance the compressor oil. Refer to «Compressor Oil Balancing (C60)»(ref-241728-S23915268682006081100000) or «Compressor Oil Balancing (C69)»(ref-241728-S34668370712006081100000) .
  2. Install the A/C compressor.
  3. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  4. Install the passenger side engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
  5. Install the air deflector and bolts. Tighten: Tighten bolts to 20 N.m (15 lb ft).
  6. Lower the vehicle.
  7. Release the drive belt tensioner.
  8. Install the drive belt to the A/C compressor.
  9. Install the drive belt to the generator pulley.
  10. Remove the caps or tape from the discharge and suction line openings.
  11. Install NEW sealing washers (3) to the discharge and suction lines.
  12. If equipped with a C69 compressor, install the discharge (5) and suction (2) lines to the compressor.
  13. Install the discharge line (5) to compressor nut (4). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  14. Install the suction line (2) to compressor nut (1). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  15. Remove the caps or tape from the discharge and suction line openings.
  16. Install NEW sealing washers (2) to the discharge and suction lines.
  17. If equipped with a C60 compressor, install the discharge (3) and suction (5) lines to the compressor.
  18. Install the suction line (5) to compressor nut (4). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  19. Install the discharge line (3) to compressor nut (4). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  20. Connect the A/C compressor electrical connector.
  21. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  22. Leak test the A/C fittings using the J 39400-A .
  1. Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Remove the high pressure relief valve (1).
  3. Remove and discard the O-ring seal (2).
  4. Cap or tape the pressure relief valve port.
  1. Lubricate and install the NEW O-ring seal (2). Refer to «O-Ring Replacement»(ref-241728-S21048582672006081100000) .
  2. Remove the cap or tape from the pressure relief valve port. NOTE: Refer to «Fastener Notice»(ref-241680-S40752786592006081100000) in Cautions and Notices.
  3. Install the high pressure relief valve (1). Tighten: Tighten the valve to 12 N.m (106 lb in).
  4. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  5. Leak test the fitting of the component using J 39400-A .
  1. Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
  3. Remove the high pressure relief valve (1).
  4. Remove and discard the O-ring seal (2).
  5. Cap or tape the pressure relief valve port.
  1. Lubricate and install the NEW O-ring seal (2). Refer to «O-Ring Replacement»(ref-241728-S21048582672006081100000) .
  2. Remove the cap or tape from the pressure relief valve port.
  3. Install the high pressure relief valve (1). Tighten: Tighten the valve to 12 N.m (106 lb in).
  4. Lower the vehicle.
  5. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  6. Leak test the fitting of the component using J 39400-A .
  1. Remove the seal washer from the A/C refrigerant component.
  2. Inspect the seal washer for any signs of damage.
  3. Inspect the A/C refrigerant components for damage or burrs. Repair 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. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
  3. Carefully install the new seal washer onto the A/C refrigerant component.
  4. The washer must completely bottom against the surface of the fitting.
  5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.
  1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure 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.
  4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
  5. Discard the O-ring seal.
  1. Inspect the new O-ring seal for any sign or cracks, cuts or damage. Replace if necessary.
  2. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.
  3. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
  4. Carefully slide the new O-ring seal onto the A/C refrigerant component.
  5. The O-ring seal must be fully seated.
  6. Assemble the A/C components. Refer to the appropriate repair procedure. 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.
IMPORTANTCap or tape the open air conditioning (A/C) components immediately in order to prevent system contamination.
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Remove the discharge hose to A/C condenser bolt (3).
  3. Remove the discharge hose from the A/C condenser.
  4. Remove and discard the sealing washer (2).
  5. Cap or tape the discharge port on the A/C condenser.
  6. Remove the discharge hose to A/C compressor nut.
  7. Remove the discharge hose (3) from the A/C compressor.
  8. Remove and discard the sealing washer (2).
  9. Cap or tape the A/C compressor discharge port.
  10. Remove the discharge hose.
  1. Install a NEW sealing washer (2) onto the A/C compressor side of the discharge hose. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  2. Remove the cap or tape from the A/C compressor discharge port.
  3. Install the discharge hose (3) to the A/C compressor.
  4. Install the discharge hose to A/C compressor nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install a NEW sealing washer (2) to the A/C condenser side of the discharge hose. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  6. Remove the cap or tape from the discharge port on the A/C condenser.
  7. Install the discharge hose to the A/C condenser.
  8. Install the discharge hose to A/C condenser bolt. Tighten: The bolt to 16 N.m (12 lb ft).
  9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  10. Leak test the fittings of the A/C components using the J 39400-A .
IMPORTANTCap or tape the open air conditioning (A/C) components immediately in order to prevent system contamination.
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Remove the discharge hose to A/C condenser bolt (3).
  3. Remove the discharge hose from the A/C condenser.
  4. Remove and discard the sealing washer (2).
  5. Cap or tape the discharge port on the A/C condenser.
  6. Remove the discharge hose to A/C compressor nut (4).
  7. Remove the discharge hose (5) from the A/C compressor.
  8. Remove and discard the sealing washer (3).
  9. Cap or tape the A/C compressor discharge port.
  10. Remove the discharge hose.
  1. Install a NEW sealing washer (3) onto the A/C compressor side of the discharge hose. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  2. Remove the cap or tape from the A/C compressor discharge port.
  3. Install the discharge hose (5) to the A/C compressor.
  4. Install the discharge hose to A/C compressor nut (4). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install a NEW sealing washer (2) to the A/C condenser side of the discharge hose. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  6. Remove the cap or tape from the discharge port on the A/C condenser.
  7. Install the discharge hose to the A/C condenser.
  8. Install the discharge hose to A/C condenser bolt. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  10. Leak test the fittings of the A/C components using the J 39400-A .
IMPORTANTCap or tape the open air conditioning (A/C) components immediately in order to prevent system contamination.
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Remove the suction hose to A/C evaporator tube bolt (1).
  3. Remove the suction hose from the A/C evaporator tube.
  4. Remove and discard the sealing washer (2).
  5. Cap or tape off the A/C evaporator tube.
  6. Disconnect the A/C compressor electrical connector.
  7. Remove the suction hose to A/C compressor nut.
  8. Remove the suction hose (5) from the A/C compressor.
  9. Remove and discard the sealing washer (2).
  10. Cap or tape the suction port on the A/C compressor.
  11. Remove the suction hose.
  1. Install a NEW sealing washer (2) onto the A/C compressor end of the suction hose. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  2. Remove the cap or tape from the suction port on the A/C compressor.
  3. Install the suction hose (5) to the A/C compressor.
  4. Install the suction hose to A/C compressor nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install a NEW sealing washer (2) to the evaporator tube end of the suction hose. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  6. Remove the cap or tape from the evaporator tube.
  7. Install the suction hose to the A/C evaporator tube.
  8. Install the suction hose to A/C evaporator tube bolt (1). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  9. Connect the A/C compressor electrical connector.
  10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  11. Leak test the fittings of the A/C components using the J 39400-A .
IMPORTANTCap or tape the open air conditioning (A/C) components immediately in order to prevent system contamination.
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Remove the suction hose to A/C evaporator tube bolt (1).
  3. Remove the suction hose from the A/C evaporator tube.
  4. Remove and discard the sealing washer (2).
  5. Cap or tape off the A/C evaporator tube.
  6. Remove the suction hose to A/C compressor nut (1).
  7. Remove the suction hose (2) from the A/C compressor.
  8. Remove and discard the sealing washer (3).
  9. Cap or tape the suction port on the A/C compressor.
  10. Remove the suction hose.
  1. Install a NEW sealing washer (3) onto the A/C compressor end of the suction hose. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  2. Remove the cap or tape from the suction port on the A/C compressor.
  3. Install the suction hose (2) to the A/C compressor.
  4. Install the suction hose to A/C compressor nut (1). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install a NEW sealing washer (2) to the evaporator tube end of the suction hose. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  6. Remove the cap or tape from the evaporator tube.
  7. Install the suction hose to the A/C evaporator tube.
  8. Install the suction hose to A/C evaporator tube bolt (1). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  9. Connect the A/C compressor electrical connector.
  10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  11. Leak test the fittings of the A/C components using the J 39400-A .
IMPORTANTCap or tape the open air conditioning (A/C) components immediately in order to prevent system contamination.
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-241686-S23045185402006081100000) .
  2. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  3. Remove the suction line to evaporator outlet tube bolt (1).
  4. Remove the suction line from the evaporator outlet tube.
  5. Cap or tape the suction line opening.
  6. Remove and discard the sealing washer (2).
  7. Reposition the heater hoses in order to access the thermal expansion valve (TXV).
  8. Remove the evaporator inlet/outlet tube block nut at the TXV.
  9. Remove the evaporator inlet/outlet tube block from the TXV.
  10. Remove and discard the sealing washers.
  11. Cap or tape the TXV openings.
  12. Remove the evaporator inlet tube to condenser bolt (2).
  13. Remove the evaporator inlet tube (5) from the condenser.
  14. Remove and discard the sealing washer.
  15. Cap or tape the condenser opening.
  16. Remove the electrical connector (3) from bracket.
  17. Remove the evaporator inlet/outlet tube bracket bolt (4).
  18. Remove the evaporator inlet/outlet tube clip to shock tower nut (6).
  19. Remove the evaporator inlet/outlet tube assembly.
  20. Remove the evaporator outlet tube (8) from the inlet tube (5).
  1. Install the evaporator outlet tube (8) to the inlet tube (5).
  2. Install the evaporator inlet/outlet tube assembly.
  3. Install the evaporator inlet/outlet tube clip to shock tower nut (6). Tighten: Tighten the nut to 5.5 N.m (49 lb in).
  4. Install a NEW sealing washer to the condenser end of the evaporator inlet tube.
  5. Remove the cap or tape from the condenser opening.
  6. Install the evaporator inlet tube (5) to the condenser.
  7. Install the evaporator inlet tube to condenser bolt (2). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  8. Install the evaporator inlet/outlet tube bracket bolt (4). Tighten: Tighten the bolt to 27 N.m (20 lb ft).
  9. Install the electrical connector (3) to bracket.
  10. Install NEW sealing washers to the TXV end of the evaporator inlet/outlet tube.
  11. Remove the caps or tape from the TXV openings.
  12. Install the evaporator inlet/outlet tube block to the TXV.
  13. Install the evaporator inlet/outlet tube block nut at the TXV. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  14. Install a NEW sealing washer (2) to the suction line.
  15. Remove the cap or tape from the suction line opening.
  16. Install the suction line to the evaporator outlet tube.
  17. Install the suction line to evaporator outlet tube bolt (1). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  18. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  19. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-241686-S23045185402006081100000) .
  1. Remove the underhood electrical center cover.
  2. Locate the compressor relay. Refer to «Electrical Center Identification Views»(ref-241683-S36767445002006081100000) to locate the A/C compressor relay.
  3. Using the J 43244 position the tool on opposing corners of the compressor relay.
  4. Remove the relay from the electrical center.
  1. Install the compressor relay in the same position as removed.
  2. Install the electrical center cover.
  1. Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Remove the A/C refrigerant valve (2).
  3. Remove and discard the O-ring seal (3).
  1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil.
  2. Install the O-ring seal (3) onto the valve if necessary.
  3. Install the A/C refrigerant valve (2). Tighten: Tighten the valve to 11 N.m (98 lb in).
  4. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  5. Leak test the fitting valve area using the J 39400-A .
  6. Install the service port cap (1).
IMPORTANTCap or tape the open air conditioning (A/C) lines immediately in order to prevent system contamination.
  1. Remove the A/C condenser. Refer to «Condenser Replacement»(ref-241728-S30039120592006081100000) .
  2. Cap or tape the open A/C lines.
  3. Remove the receiver dehydrator upper bracket screw (4).
  4. Remove the receiver dehydrator lower bolts (3).
  5. Remove the receiver dehydrator.
  6. Remove and discard the receiver dehydrator lower sealing washers.
  7. Cap or tape the condenser lower openings.
  1. If replacing the receiver dehydrator, add the specified amount of PAG oil directly to the receiver dehydrator. Refer to «Refrigerant System Capacities»(ref-241728-S13874285892006081100000) .
  2. Remove the cap or tape from the condenser lower openings.
  3. Install NEW lower receiver dehydrator sealing washers.
  4. Install the receiver dehydrator.
  5. Install the receiver dehydrator lower bolts (3). Tighten: Tighten the bolts to 16 N.m (12 lb ft).
  6. Install the receiver dehydrator upper bracket screw (4). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  7. Remove the caps or tape from the open A/C lines.
  8. Install the A/C condenser. Refer to «Condenser Replacement»(ref-241728-S30039120592006081100000) .
IMPORTANTCap or tape the open evaporator inlet and outlet tubes immediately in order to prevent system contamination.
  1. Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Reposition the heater hoses for clearance, if necessary.
  3. Remove the evaporator tube block to the thermal expansion valve (TXV) nut.
  4. Disconnect the evaporator inlet and outlet tube block from the TXV.
  5. Remove the evaporator inlet tube from the outlet tube.
  6. Remove and discard the sealing washers.
  7. Cap or tape off the evaporator inlet and outlet tubes.
  8. Remove the TXV to evaporator bolts.
  9. Remove the TXV from the evaporator core.
  10. Remove and discard the TXV sealing washers.
  1. Install NEW sealing washers onto the evaporator core.
  2. Install the TXV to the evaporator core.
  3. Install the TXV to evaporator bolts. Tighten: Tighten the bolts to 3.2 N.m (28 lb in).
  4. Remove the caps or tape from the evaporator inlet and outlet tubes.
  5. Install NEW sealing washers onto the inlet and outlet tubes.
  6. Install the evaporator inlet tube to the outlet tube.
  7. Connect the evaporator inlet and outlet tube block to the TXV.
  8. Install the evaporator tube block to the TXV nut. Tighten: Tighten the bolts to 16 N.m (12 lb ft).
  9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  10. Leak test the fittings using the J 39400-A .
  1. Disconnect the air conditioning (A/C) refrigerant pressure sensor electrical connector (1).
  2. Remove the A/C refrigerant pressure sensor (2).
  3. Inspect and replace the O-ring seal (3) as necessary.
IMPORTANTDO NOT allow any of the mineral base 525 viscosity refrigerant oil on the O-ring seal to enter the refrigerant system.
  1. Lightly coat the O-ring seal (3) with mineral base 525 viscosity oil.
  2. Install the A/C refrigerant pressure sensor (2). Tighten: Tighten the sensor to 5 N.m (44 lb in).
  3. Connect the A/C refrigerant pressure sensor electrical connector (1).
  4. Leak test the fitting using the J 39400-A .
  1. Remove the evaporator core. Refer to «Evaporator Core Replacement»(ref-241728-S31190239912006081100000) .
  2. Disconnect the evaporator temperature sensor clips.
  3. Remove the evaporator temperature sensor.
IMPORTANTThe tip of the temperature sensor should be located at the center of the 4th fin from the passenger side. The sensor should not come in contact with the evaporator surface.
  1. Install the evaporator temperature sensor.
  2. Connect the evaporator temperature sensor clips.
  3. Install the evaporator core. Refer to «Evaporator Core Replacement»(ref-241728-S31190239912006081100000) .
  1. Remove the radiator. Refer to «Radiator Replacement»(ref-241700-S04994948312006081100000) .
  2. Remove the air conditioning (A/C) condenser.
  3. Remove the receiver dehydrator, if necessary. Refer to «Receiver Dehydrator Replacement»(ref-241728-S09084990472006081100000) .
  1. Install the receiver dehydrator, if necessary. Refer to «Receiver Dehydrator Replacement»(ref-241728-S09084990472006081100000) .
  2. If replacing the condenser add the specified amount of polyalkylene glycol (PAG) oil directly to the condenser. Refer to «Refrigerant System Capacities»(ref-241728-S13874285892006081100000) .
  3. Install the A/C condenser.
  4. Install the radiator. Refer to «Radiator Replacement»(ref-241700-S04994948312006081100000) .
  5. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  6. Leak test the fittings using the J 39400-A .
  1. Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
  3. Set the heating, ventilation and air conditioning (HVAC) controls in the vent setting to close the defroster door.
  4. Remove the blower motor. Refer to «Blower Motor Replacement»(ref-241728-S21270469552006081100000) .
  5. Disconnect the electrical connector from the blower motor resistor.
  6. Disconnect the electrical connector from the evaporator temperature sensor.
  7. Disconnect all of the HVAC actuator electrical connectors.
  8. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-241678-S40138688332006081100000) in Instrument Panel, Gages and Console.
  9. Remove the evaporator outlet tube nut.
  10. Disconnect the evaporator outlet tube and evaporator inlet tube from the thermal expansion valve (TXV).
  11. Remove and discard the sealing washers.
  12. Remove the heater inlet and outlet hoses. Refer to «Heater Hose/Pipe Replacement - Inlet/Outlet»(ref-241728-S16933141722006081100000) .
  13. Remove the HVAC module nuts.
IMPORTANTEnsure proper alignment of the HVAC module and drain tube through the cowl.
  1. Install the HVAC module.
  2. Instal the HVAC module to dash panel sound barrier nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  3. Install the heater inlet and outlet hoses. Refer to «Heater Hose/Pipe Replacement - Inlet/Outlet»(ref-241728-S16933141722006081100000) .
  4. Install NEW sealing washers.
  5. Connect the evaporator inlet and outlet tube block to the TXV.
  6. Install the evaporator tube block nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  7. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-241678-S40138688332006081100000) in Instrument Panel, Gages and Console.
  8. Connect all of the HVAC actuator electrical connectors.
  9. Connect the electrical connector to the evaporator temperature sensor.
  10. Connect the electrical connector to the blower motor resistor.
  11. Install the blower motor. Refer to «Blower Motor Replacement»(ref-241728-S21270469552006081100000) .
  12. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
  13. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  14. Leak test the fittings using the J 39400-A .
  1. Remove the heating, ventilation and air conditioning (HVAC) module assembly. Refer to «HVAC Module Assembly Replacement»(ref-241728-S38162865792006081100000) .
  2. Remove the heater outlet duct screws.
  3. Remove the heater outlet duct.
  4. Remove the heater core cover screws (1).
  5. Remove heater core cover (2).
  6. Remove the heater core pipe screw.
  7. Remove the heater core.
  8. Remove the HVAC module to dash panel sound barrier seal.
  9. Remove the lower HVAC module screws (1).
  10. Separate the upper and lower HVAC module halves.
  11. Remove the evaporator core.
  12. Remove the evaporator temperature sensor.
  13. Remove the thermal expansion valve (TXV) screws.
  14. Remove the TXV from the evaporator core.
  15. Remove and discard the sealing washers.
  1. If replacing the evaporator core add the specified amount of polyalkylene glycol (PAG) oil directly to the evaporator core. Refer to «Refrigerant System Capacities»(ref-241728-S13874285892006081100000) .
  2. Install the new sealing washers onto the evaporator line. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  3. Install the TXV to the evaporator core.
  4. Install the TXV mounting screws. Tighten: Tighten the screws to 3.2 N.m (28 lb in).
  5. Install the evaporator temperature sensor.
  6. Install the evaporator core.
  7. Align and install the upper case to the lower case.
  8. Install the lower HVAC module screws (1). Tighten: Tighten the screws to 1.2 N.m (11 lb in).
  9. Install the HVAC module to dash panel sound barrier seal.
  10. Install the heater core.
  11. Install the heater core pipe screw. Tighten: Tighten the screw to 1.2 N.m (11 lb in).
  12. Install heater core cover (2).
  13. Install the heater core cover screws (1). Tighten: Tighten the screws to 1.2 N.m (11 lb in).
  14. Install the heater outlet duct.
  15. Install the heater outlet duct screws. Tighten: Tighten the screws to 1.2 N.m (11 lb in).
  16. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-241728-S38162865792006081100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .
  2. Release the quick connect.
  3. Disconnect the inlet heater hose (1) at the engine.
  4. Disconnect the outlet heater hose (2) at the engine.
  5. Using the J 38185 or SA911E hose clamp pliers, disengage the inlet hose clamp at the module.
  6. Using the J 38185 or SA911E hose clamp pliers, disengage the outlet hose clamp at the module.
  7. If equipped with rear air conditioning, disengage the inlet and outlet hose clamps from the rear auxiliary pipes using the J 38185 or SA911E.
  8. Remove the inlet or outlet hose.
  1. Install the inlet or outlet hose.
  2. If equipped with rear air conditioning, engage the inlet and outlet hose clamps at the rear auxiliary pipes.
  3. Engage the outlet hose clamp at the module.
  4. Engage the inlet hose clamp at the module.
  5. Connect the outlet heater hose (2) at the engine.
  6. Connect the inlet heater hose (1) at the engine.
  7. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .
  1. Open the instrument panel (I/P) compartment door.
  2. Remove the rear inside I/P compartment door.
  3. Open the air filter access door.
  4. Remove the right hand air filter from the HVAC module.
  5. Slide the left hand air filter to the HVAC module opening. Remove the left hand air filter from the HVAC module.
  1. Install the left hand air filter into the HVAC module opening. Slide the left hand air filter toward the left side of the HVAC module.
  2. Install the right hand air filter into the HVAC module opening.
  3. Close the air filter access door.
  4. Install the rear inside I/P compartment door.
  5. Close the I/P compartment door.
  1. Remove the blower motor. Refer to «Blower Motor Replacement»(ref-241728-S21270469552006081100000) .
  2. Disconnect the electrical connector from the blower motor resistor.
  3. Loosen the rearward blower motor resistor screws (3).
  4. Remove the forward blower motor resistor screw (3).
  5. Remove the blower motor resistor (4).
  1. Install the blower motor resistor (4).
  2. Install and snug the forward blower motor resistor screw.
  3. Tighten the rearward blower motor resistor screws (3). Tighten: Tighten the screws to 1.2 N.m (11 lb in).
  4. Connect the electrical connector to the blower motor resistor.
  5. Install the blower motor. Refer to «Blower Motor Replacement»(ref-241728-S21270469552006081100000) .
  1. Remove the right side instrument panel (I/P) insulator. Refer to «Knee Bolster, Insulator, Molding Replacement - Instrument Panel»(ref-241678-S36361698522006081100000) in Instrument Panel, Gages and Console.
  2. Disconnect the blower motor electrical connector (1).
  3. Remove the blower motor screws (1).
  4. Remove the blower motor (2).
  1. Install the blower motor (2).
  2. Install the blower motor screws (1). Tighten: Tighten the screws to 1.2 N.m (11 lb in).
  3. Connect the blower motor electrical connector (1).
  4. Install the right side I/P insulator. Refer to «Knee Bolster, Insulator, Molding Replacement - Instrument Panel»(ref-241678-S36361698522006081100000) in Instrument Panel, Gages and Console.

Scheme 3

Scheme 3: Air Outlet Replacement - Instrument Panel
Scheme 3: Air Outlet Replacement - Instrument Panel
CalloutComponent Name
NOTE: Refer to Fastener Notice in Cautions and Notices. Fastener Tightening Specifications: Refer to Fastener Tightening Specifications .
I/P A/C Outlet Assembly Replacement - Right
1Outlet Assembly, Instrument Panel (I/P) A/C Right
I/P A/C Outlet Assembly Replacement - Center
2Panel, I/P Accessory Trim
3Outlet Assembly, I/P A/C Center Tip: Pull rearward of the I/P to remove. Disconnect the electrical connectors from the switches. Remove the switches if replacing the outlet assembly.
I/P A/C Outlet Assembly Replacement - Left
4Molding Assembly, I/P Steering Column Opening
5Outlet Assembly, I/P A/C Left Tip: Pull rearward of the I/P to remove. Disconnect the electrical connector from the headlamp switch. Remove the headlamp switch if replacing the outlet assembly.
NOTE
Refer to Fastener Notice in Cautions and Notices.

Air Outlet Replacement - Instrument Panel

  1. Remove the instrument panel (I/P) compartment. Refer to «Compartment Assembly, Door, Striker, Latch Replacement - Instrument Panel»(ref-241678-S24586229232006081100000) in Instrument Panel, Gages and Console.
  2. Remove the center floor air outlet. Refer to «Air Outlet Duct Replacement - Center Floor»(ref-241728-S41013723552006081100000) .
  3. Remove the floor air outlet screws.
  4. Remove the floor air outlet.
  1. Install the floor air outlet.
  2. Install the floor air outlet screws. Tighten: Tighten the screws to 1.2 N.m (11 lb in).
  3. Install the center floor air outlet. Refer to «Air Outlet Duct Replacement - Center Floor»(ref-241728-S41013723552006081100000) .
  4. Install the I/P compartment. Refer to «Compartment Assembly, Door, Striker, Latch Replacement - Instrument Panel»(ref-241678-S24586229232006081100000) in Instrument Panel, Gages and Console.
  1. Remove the front seats. Refer to «Seat Replacement - Front Bucket»(ref-241729-S23102964762006081100000) in Seats.
  2. Reposition the front of the carpet rearward.
  3. Remove the floor duct brace nuts (1).
  4. Remove the floor duct brace (2).
  5. Remove the floor duct (3) from the center floor duct (2).
  6. Remove the center floor duct (2).
  1. Install the center floor duct (2).
  2. Install the floor duct (3) to the center floor duct (2).
  3. Install the floor duct brace (2).
  4. Install the floor duct brace nuts (1). Tighten: Tighten the nuts to 10 N.m (89 lb in).
  5. Position the front of the carpet forward.
  6. Install the front seats. Refer to «Seat Replacement - Front Bucket»(ref-241729-S23102964762006081100000) in Seats.
  1. Set the HVAC controls in the VENT mode to close the defroster door.
  2. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-241678-S40138688332006081100000) in Instrument Panel, Gages and Console.
  3. Remove the defroster outlet duct bolts.
  4. Using the J 38778 remove the defroster outlet duct retaining clips.
  5. Remove the defroster outlet duct from the I/P carrier.
  1. Install the defroster outlet duct to the I/P carrier.
  2. Install the defroster outlet duct bolts. Tighten: Tighten the bolts to 1.2 N.m (11 lb in).
  3. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-241678-S40138688332006081100000) in Instrument Panel, Gages and Console.
  1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(ref-241678-S31508660992006081100000) in Instrument Panel, Gages and Console.
  2. Lift up on the retaining tab and rotate the air distribution extension duct (1, 2).
  3. Remove the air distribution extension duct (1, 2) from the crosscar beam.
  1. Align the tabs on the air distribution extension duct (1, 2) with the slots in the crosscar beam.
  2. Rotate the air distribution extension duct to secure the retaining tabs to the crosscar beam.
  3. Install the I/P assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(ref-241678-S31508660992006081100000) in Instrument Panel, Gages and Console.
  1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(ref-241678-S31508660992006081100000) in Instrument Panel, Gages and Console.
  2. Remove the center air distribution duct nuts.
  3. Remove the center air distribution duct from the crosscar beam.
  1. Position the center air distribution duct to the crosscar beam.
  2. Install the center air distribution duct nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  3. Install the I/P assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(ref-241678-S31508660992006081100000) in Instrument Panel, Gages and Console.
  1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(ref-241678-S31508660992006081100000) in Instrument Panel, Gages and Console.
  2. Remove the side window duct from the I/P carrier.
  3. Remove side window duct from the defroster duct.
  1. Install the side window duct to the defroster duct.
  2. Install the side window duct to the I/P carrier.
  3. Install the I/P assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(ref-241678-S31508660992006081100000) in Instrument Panel, Gages and Console.
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-241728-S38162865792006081100000) .
  2. Remove the evaporator temperature sensor connector (1) from the case.
  3. Remove the air inlet housing bolts/screws.
  4. Remove the air inlet housing.
  5. Remove the right side HVAC module bracket bolts/screws (1).
  6. Remove the right side HVAC module bracket (2).
  7. Remove the upper HVAC module bolt/screw.
  8. Remove the HVAC module to dash panel sound barrier seal (1).
  9. Remove the heater outlet duct bolts/screws.
  10. Remove the heater outlet duct.
  11. Remove the heater core cover bolts/screws (1).
  12. Remove the heater core cover (2).
  13. Remove the heater core pipe bolt/screw (1).
  14. Remove the heater core (2).
  15. Remove the lower HVAC module bolts/screws (1).
  16. Separate the HVAC module case halves.
  17. Remove the air temperature actuator bolts/screws (1).
  18. Remove the air temperature actuator (2).
  19. Remove the air temperature actuator lever (3).
  20. Remove the air temperature door (4).
  1. Install the air temperature door (4).
  2. Install the air temperature actuator lever (3).
  3. Install the air temperature actuator (2).
  4. Install the air temperature actuator bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  5. Align and install the upper module case to the lower module case.
  6. Install the lower HVAC module bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  7. Install the heater core (2).
  8. Install the heater core pipe bolt/screw (1). Tighten: Tighten he bolts/screws to 1.2 N.m (11 lb in).
  9. Install the heater core cover (2).
  10. Install the heater core cover bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  11. Install the heater outlet duct.
  12. Install the heater outlet duct bolts/screws. Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  13. Install the HVAC module to dash panel sound barrier seal (1).
  14. Install the upper HVAC module bolt/screw. Tighten: Tighten the bolt/screw to 1.2 N.m (11 lb in).
  15. Install the right side HVAC module bracket (2).
  16. Install the right side HVAC module bracket bolts/screws (1). Tighten: Tighten the bolts/screws to 1.4 N.m (12 lb in).
  17. Install the air inlet housing.
  18. Install the air inlet housing bolts/screws. Tighten: Tighten the bolt/screw to 1.2 N.m (11 lb in).
  19. Install the evaporator temperature sensor connector (1) to the case.
  20. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-241728-S38162865792006081100000) .
  21. Re-calibrate the actuators. Refer to «Re-Calibrating Actuators»(ref-241727-S21722653322006081100000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-241728-S38162865792006081100000) .
  2. Remove the evaporator temperature sensor connector (1) from the case.
  3. Remove the air inlet housing bolts/screws.
  4. Remove the air inlet housing.
  5. Remove the right side HVAC module bracket bolts/screws (1).
  6. Remove the right side HVAC module bracket (2).
  7. Remove the upper HVAC module bolt/screw.
  8. Remove the HVAC module to dash panel sound barrier seal (1).
  9. Remove the heater outlet duct bolts/screws.
  10. Remove the heater outlet duct.
  11. Remove the heater core cover bolts/screws (1).
  12. Remove the heater core cover (2).
  13. Remove the heater core pipe bolt/screw (1).
  14. Remove the heater core (2).
  15. Remove the lower HVAC module bolts/screws (1).
  16. Separate the HVAC module case halves.
  17. Remove the ride side air temperature actuator bolts/screws (1).
  18. Remove the right side air temperature actuator (2).
  19. Remove the right side air temperature actuator levers (3, 4 and 5).
  20. Remove the right side air temperature door (6).
  1. Install the right side air temperature door (6).
  2. Install the right side air temperature actuator levers.
  3. Check and correct the engagement between the actuator levers (1, 2). Install the actuator lever (2). Align the primary tooth (4) of the actuator lever (1) with the gap (3) in the actuator lever (2).
  4. Install the right side air temperature actuator (2).
  5. Install the ride side air temperature actuator bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  6. Align and install the upper module case to the lower module case.
  7. Install the lower HVAC module bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  8. Install the heater core (2).
  9. Install the heater core pipe bolt/screw (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  10. Install the heater core cover (2).
  11. Install the heater core cover bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  12. Install the heater outlet duct.
  13. Install the heater outlet duct bolts/screws. Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  14. Install the HVAC module to dash panel sound barrier seal (1).
  15. Install the upper HVAC module bolt/screw. Tighten: Tighten the bolt/screw to 1.2 N.m (11 lb in).
  16. Install the right side HVAC module bracket (2).
  17. Install the right side HVAC module bracket bolts/screws (1). Tighten: Tighten the bolts/screws to 1.4 N.m (12 lb in).
  18. Install the air inlet housing.
  19. Install the air inlet housing bolts/screws. Tighten: Tighten the bolt/screw to 1.2 N.m (11 lb in).
  20. Install the evaporator temperature sensor connector (1) to the case.
  21. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-241728-S38162865792006081100000) .
  22. Re-calibrate the actuators. Refer to «Re-Calibrating Actuators»(ref-241727-S21722653322006081100000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-241728-S38162865792006081100000) .
  2. Remove the evaporator temperature sensor connector (1) from the case.
  3. Remove the air inlet housing bolts/screws.
  4. Remove the air inlet housing.
  5. Remove the right side HVAC module bracket bolts/screws (1).
  6. Remove the right side HVAC module bracket (2).
  7. Remove the upper HVAC module bolt/screw.
  8. Remove the HVAC module to dash panel sound barrier seal (1).
  9. Remove the heater outlet duct bolts/screws.
  10. Remove the heater outlet duct.
  11. Remove the heater core cover bolts/screws (1).
  12. Remove the heater core cover (2).
  13. Remove the heater core pipe bolt/screw (1).
  14. Remove the heater core (2).
  15. Remove the lower HVAC module bolts/screws (1).
  16. Separate the HVAC module case halves.
  17. Remove the left side air temperature actuator bolts/screws (1).
  18. Remove the left side air temperature actuator (2).
  19. Remove the left side air temperature actuator lever (3).
  20. Remove the left side air temperature door (4).
  1. Install the left side air temperature door (4).
  2. Install the left side air temperature actuator lever (3).
  3. Install the left side air temperature actuator (2).
  4. Install the left side air temperature actuator bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  5. Align and install the upper module case to the lower module case.
  6. Install the lower HVAC module bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  7. Install the heater core (2).
  8. Install the heater core pipe bolt/screw (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  9. Install the heater core cover (2).
  10. Install the heater core cover bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  11. Install the heater outlet duct.
  12. Install the heater outlet duct bolts/screws. Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  13. Install the HVAC module to dash panel sound barrier seal (1).
  14. Install the upper HVAC module bolt/screw. Tighten: Tighten the bolt/screw to 1.2 N.m (11 lb in).
  15. Install the right side HVAC module bracket (2).
  16. Install the right side HVAC module bracket bolts/screws (1). Tighten: Tighten the bolts/screws to 1.4 N.m (12 lb in).
  17. Install the air inlet housing.
  18. Install the air inlet housing bolts/screws. Tighten: Tighten the bolt/screw to 1.2 N.m (11 lb in).
  19. Install the evaporator temperature sensor connector (1) to the case.
  20. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-241728-S38162865792006081100000) .
  21. Re-calibrate the actuators. Refer to «Re-Calibrating Actuators»(ref-241727-S21722653322006081100000) .
  1. Set the HVAC controls in the vent setting to close the defroster door.
  2. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-241678-S40138688332006081100000) in Instrument Panel, Gages and Console.
  3. Remove the defroster cover bolts/screws (1).
  4. Remove the defroster cover (2).
  5. Remove the defrost actuator bolts/screws (4).
  6. Remove the defrost actuator (3).
  7. Remove the defrost actuator door (5).
  1. Install the defrost actuator door (5).
  2. Install the defrost actuator (3).
  3. Install the defrost actuator bolts/screws (4). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  4. Install the defroster cover (2).
  5. Install the defroster cover bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  6. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-241678-S40138688332006081100000) in Instrument Panel, Gages and Console.
  7. Re-calibrate the actuators. Refer to «Re-Calibrating Actuators»(ref-241727-S21722653322006081100000) .
  1. Remove the heater outlet duct. Refer to «Air Outlet Replacement - Floor»(ref-241728-S35205648892006081100000) .
  2. Remove the mode actuator. Refer to «Mode Actuator Replacement»(ref-241727-S31287101672006081100000) .
  3. Remove the mode door actuator mounting bracket screws.
  4. Remove the mode door actuator mounting bracket.
  5. Disconnect and remove the floor air door lever from the floor air door.
  6. Remove the floor air door from the HVAC module.
  1. Install the floor air door into the HVAC module.
  2. Install the floor air door lever into the floor air door.
  3. Install the mode door actuator mounting bracket.
  4. Install the mode door actuator mounting bracket screws. Tighten: Tighten the screws to 0.9 N.m (8 lb in).
  5. Install the mode actuator. Refer to «Mode Actuator Replacement»(ref-241727-S31287101672006081100000) .
  6. Install the heater outlet duct. Refer to «Air Outlet Replacement - Floor»(ref-241728-S35205648892006081100000) .
  1. Remove the defroster door. Refer to «Defroster Door Replacement»(ref-241728-S14510761192006081100000) .
  2. Remove the air distribution case cover bolts/screws (1).
  3. Remove the air distribution case cover.
  4. Remove the mode actuator bolts/screws (1).
  5. Remove the mode actuator (2).
  6. Remove the mode actuator lever cover bolts/screws (3).
  7. Remove the mode actuator lever cover (4).
  8. Remove the mode actuator cam (5).
  9. Remove the mode actuator levers (6, 7 and 8).
  10. Remove the mode door (9).
  1. Install the mode door (9).
  2. Install the mode actuator levers (3, 4 and 6). The pin on lever (4) should be seen through the opening in lever (6).
  3. Install the mode actuator cam (1). The pin on lever (3) should be seen through this opening (2) in the cam. The pin on lever (6) should be seen through this opening (5) in the cam.
  4. Install the mode actuator lever cover (4).
  5. Install the mode actuator lever cover bolts/screws (3). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  6. Install the mode actuator (2).
  7. Install the mode actuator bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  8. Install the air distribution case cover.
  9. Install the air distribution case cover bolts/screws (1). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  10. Install the defroster door. Refer to «Defroster Door Replacement»(ref-241728-S14510761192006081100000) .
  11. Re-calibrate the actuators. Refer to «Re-Calibrating Actuators»(ref-241727-S21722653322006081100000) .
  1. Remove the heater core cover. Refer to «Heater Core Cover Replacement»(ref-241728-S09641928032006081100000) .
  2. Remove the mode actuator bolts/screws (1).
  3. Remove the mode actuator (2).
  4. Remove the mode actuator lever cover bolts/screws (3).
  5. Remove the mode actuator lever cover (4).
  6. Remove the mode actuator cam (5).
  7. Remove the mode actuator lever (6).
  8. Remove the secondary mode door (7).
  1. Install the secondary mode door (7).
  2. Install the mode actuator levers (4, 6). The pin on lever (4) should be seen through the opening in lever (6).
  3. Install the mode actuator cam (1). The pin on lever (6) should be seen through this opening (5) in the cam.
  4. Install the mode actuator lever cover (4).
  5. Install the mode actuator lever cover bolts/screws (3). Tighten: The bolts/screws to 1.2 N.m (11 lb in).
  6. Install the mode actuator (2).
  7. Install the mode actuator bolts/screws (1). Tighten: The bolts/screws to 1.2 N.m (11 lb in).
  8. Install the heater core cover. Refer to «Heater Core Cover Replacement»(ref-241728-S09641928032006081100000) .
  1. Remove the heater core cover. Refer to «Heater Core Cover Replacement»(ref-241728-S09641928032006081100000) .
  2. Remove the right hand air temperature actuator. Refer to «Air Temperature Actuator Replacement - Right (Dual Zone)»(ref-241727-S42801610872006081100000) .
  3. Remove the right hand air temperature mounting bracket screws.
  4. Remove the right hand air temperature mounting bracket.
  5. Disconnect and remove the right hand mode door lever from the mode door.
  6. Disconnect and remove the secondary mode door lever from the secondary mode door.
  7. Remove the secondary mode door from the HVAC module.
  1. Install the secondary mode door.
  2. Connect the secondary mode door lever to the secondary mode door.
  3. Connect the right hand mode door lever to the mode door.
  4. Install the right hand air temperature mounting bracket.
  5. Install the right hand air temperature mounting bracket screws. Tighten: Tighten the screws to 0.9 N.m (8 lb in).
  6. Install the right hand air temperature actuator. Refer to «Air Temperature Actuator Replacement - Right (Dual Zone)»(ref-241727-S42801610872006081100000) .
  7. Install the heater core cover. Refer to «Heater Core Cover Replacement»(ref-241728-S09641928032006081100000) .
  1. Set the HVAC controls in the vent setting to close the defroster door.
  2. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-241678-S40138688332006081100000) in Instrument Panel, Gages and Console.
  3. Remove the secondary defroster door lever.
  4. Remove the secondary defroster door.
  1. Install the secondary defroster door.
  2. Install the secondary defroster door lever.
  3. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-241678-S40138688332006081100000) in Instrument Panel, Gages and Console.
  1. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-241678-S40138688332006081100000) in Instrument Panel, Gages and Console.
  2. Disconnect the evaporator temperature sensor electrical connector (1).
  3. Remove the evaporator temperature sensor electrical connector (2) from the case.
  4. Open the HVAC passenger compartment air filter access door.
  5. Remove the HVAC passenger compartment air filters.
  6. Disconnect the recirculation actuator electrical connector (1).
  7. Remove the air inlet housing bolts/screws.
  8. Remove the air inlet housing.
  9. Remove the air inlet case bolts/screws (2).
  10. Separate the air inlet case halves.
  11. Remove the recirculation door (4).
  1. Install the recirculation door (4).
  2. Align and install the left case to the right case.
  3. Install the air inlet case bolts/screws (2). Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  4. Install the air inlet housing.
  5. Install the air inlet housing bolts/screws. Tighten: Tighten the bolts/screws to 1.2 N.m (11 lb in).
  6. Connect the recirculation actuator electrical connector (1).
  7. Install the HVAC passenger compartment air filters.
  8. Close the HVAC passenger compartment air filter access door.
  9. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-241678-S40138688332006081100000) in Instrument Panel, Gages and Console.
  10. Re-calibrate the actuators. Refer to «Re-Calibrating Actuators»(ref-241727-S21722653322006081100000) .
  1. Remove the floor air outlet duct. Refer to «Air Outlet Replacement - Floor»(ref-241728-S35205648892006081100000) .
  2. Remove the heater core cover screws (1).
  3. Remove the heater core cover (2).
  1. Install the heater core cover.
  2. Install the heater core cover screws. Tighten: Tighten the screws to 1.2 N.m (11 lb in).
  3. Install the floor air outlet duct. Refer to «Air Outlet Replacement - Floor»(ref-241728-S35205648892006081100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
  2. Disconnect both of the heater hose clamps at the heater core using the J 38185 or SA9111E.
  3. Remove the heater hoses from the heater core.
  4. Cap off the heater core pipes.
  5. Remove the heater core cover. Refer to «Heater Core Cover Replacement»(ref-241728-S09641928032006081100000) .
  6. Remove the heater core pipe clamp screw.
  7. Remove the heater core.
  1. Install the heater core.
  2. Install the heater core pipe clamp screw. Tighten: Tighten the screw to 1.2 N.m (11 lb in).
  3. Install the heater core cover. Refer to «Heater Core Cover Replacement»(ref-241728-S09641928032006081100000) .
  4. Install the heater hoses to the heater core.
  5. Reposition the heater hose clamps to secure the hoses using the J 38185 .
  6. Fill the coolant. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
  1. Remove the left lower quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Left»(ref-241679-S30922318502006081100000) .
  2. Disconnect the auxiliary blower motor electrical connector.
  3. Disconnect the auxiliary blower motor resistor electrical connector.
  4. Remove the lower auxiliary air distribution duct bolts and retainers.
  5. Remove the lower auxiliary air distribution duct.
  6. Remove the auxiliary lower blower motor housing screws.
  7. Lift the auxiliary blower motor housing and remove from the HVAC module assembly.
  8. Disconnect the auxiliary temperature door actuator electrical connector.
  9. Remove the auxiliary temperature door actuator screws.
  10. Remove the auxiliary temperature door actuator.
  11. Remove the upper auxiliary HVAC module mounting bolt.
  12. Remove the auxiliary evaporator core housing screws.
  13. Remove the auxiliary evaporator core housing.
  14. Remove the auxiliary air temperature door from the auxiliary HVAC module.
  15. Remove the auxiliary air temperature door lever (1) from the auxiliary air temperature door.
  1. Install the auxiliary air temperature door lever (1) to the auxiliary air temperature door.
  2. Install the auxiliary air temperature door to the auxiliary HVAC module.
  3. Install the auxiliary evaporator core housing.
  4. Install the auxiliary evaporator core housing screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  5. Install the upper auxiliary HVAC module mounting bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  6. Install the auxiliary temperature door actuator.
  7. Install the auxiliary temperature door actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  8. Connect the auxiliary temperature door actuator electrical connector.
  9. Install the blower motor housing to the auxiliary HVAC module assembly. Align the rear tabs of the blower motor housing to the HVAC module.
  10. Install the auxiliary blower motor housing screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  11. Install the lower auxiliary air distribution duct.
  12. Install the lower auxiliary air distribution retainer.
  13. Install the lower auxiliary air distribution ducts bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  14. Connect the auxiliary blower motor resistor electrical connector.
  15. Connect the auxiliary blower motor electrical connector.
  16. Install the left lower quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Left»(ref-241679-S30922318502006081100000) .
  1. Disconnect the heater inlet and outlet hoses from the auxiliary heater inlet/outlet pipes using J 38185 or (SA9111E).
  2. Drain the coolant system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .
  3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
  4. Remove the auxiliary heater inlet/outlet pipe clip nut (1).
  5. Remove the auxiliary heater inlet/outlet pipe clip nut (1).
  6. Remove the auxiliary heater inlet/outlet pipe clip (1).
  7. Remove the auxiliary heater inlet/outlet pipe (2) clip nut (1).
  8. Remove the auxiliary heater inlet/outlet pipe clip (1).
  9. Remove the auxiliary inlet/outlet pipe (2) clip nut (1).
  10. Using the J 38185 or (SA9111E), disconnect the auxiliary heater inlet/outlet hoses (2) at the rear of the vehicle.
  11. Remove the auxiliary heater inlet/outlet hose assembly.
  1. Install the auxiliary heater inlet/outlet hoses (2) to the rear of the vehicle.
  2. Using a small flat-bladed screwdriver, release the hose clamp retention locks.
  3. Install the auxiliary inlet/outlet pipe (2) clip nut (1). Tighten: Tighten the nut to 10 N.m (89 lb in).
  4. Install the auxiliary heater inlet/outlet pipe clip (1).
  5. Install the auxiliary heater inlet/outlet pipe (2) clip nut (1). Tighten: Tighten the nut to 10 N.m (89 lb in).
  6. Install the auxiliary heater inlet/outlet pipe clip (1).
  7. Install the auxiliary heater inlet/outlet pipe clip nut (1). Tighten: TIghten the nut to 10 N.m (89 lb in).
  8. Lower the vehicle.
  9. Install the auxiliary heater inlet/outlet pipe clip nut (1). Tighten: Tighten the nut to 10 N.m (89 lb in).
  10. Install the heater inlet and outlet hoses to the auxiliary heater inlet/outlet pipes.
  11. Using a small flat-bladed screwdriver, release the hose clamp retention locks.
  12. Fill the coolant system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .
  1. Remove the accessory panel from the left rear quarter trim. Refer to «Trim Panel Replacement - Rear Quarter - Left»(ref-241679-S30922318502006081100000) .
  2. Disconnect the auxiliary blower motor resistor electrical connector.
  3. Remove the auxiliary blower motor resistor screws.
  4. Remove the auxiliary blower motor resistor from the auxiliary HVAC module assembly.
  1. Install the auxiliary blower motor resistor to the auxiliary HVAC module assembly.
  2. Install the auxiliary blower motor resistor screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Connect the auxiliary blower motor resistor electrical connector.
  4. Install the accessory panel from the left rear quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Left»(ref-241679-S30922318502006081100000) .
  1. Remove the left lower quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Right»(ref-241679-S40373754052006081100000) in Interior Trim.
  2. Disconnect the auxiliary blower motor electrical connector.
  3. Disconnect the auxiliary blower motor resistor electrical connector.
  4. Remove the lower auxiliary air distribution duct bolts and retainers.
  5. Remove the lower auxiliary air distribution duct.
  6. Remove the auxiliary blower motor housing screws.
  7. Lift the auxiliary blower motor housing and remove from the HVAC module assembly.
  8. Remove the auxiliary blower motor mounting screws.
  9. Remove the auxiliary blower motor from the blower motor housing.
  1. Install the auxiliary blower motor to the blower motor housing.
  2. Install the auxiliary blower motor mounting screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Install the blower motor housing to the auxiliary HVAC module assembly. Align the rear tabs of the blower motor housing to the HVAC module.
  4. Install the auxiliary blower motor housing screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  5. Install the lower auxiliary air distribution duct.
  6. Install the lower auxiliary air distribution retainers.
  7. Install the lower auxiliary air distribution ducts bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  8. Connect the auxiliary blower motor resistor electrical connector.
  9. Connect the auxiliary blower motor electrical connector.
  10. Install the left lower quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Right»(ref-241679-S40373754052006081100000) in Interior Trim.
  1. Remove the accessory panel. Refer to «Accessory Panel Replacement - Rear»(ref-241679-S03806905162006081100000) in Interior Trim.
  2. Remove the screws from the hinged cover.
  3. Remove the cover from the rear trim panel.
  4. Release the tabs and pull out the trim panel.
  5. Disconnect the auxiliary blower motor electrical connector.
  6. Disconnect the auxiliary blower motor resistor electrical connector.
  7. Disconnect the auxiliary air temperature actuator electrical connector.
  8. Remove the auxiliary blower motor mounting screws.
  9. Remove the auxiliary blower motor from the blower motor housing.
  1. Install the auxiliary blower motor to the blower motor housing.
  2. Install the auxiliary blower motor mounting screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Connect the auxiliary air temperature actuator electrical connector.
  4. Connect the auxiliary blower motor resistor electrical connector.
  5. Connect the auxiliary blower motor electrical connector.
  6. Install the trim panel and press firmly into the tabs.
  7. Align the cover and fasten the screws. Tighten: Tighten the screws to 2.5 N.m (22 lb in).
  8. Install the accessory panel. Refer to «Accessory Panel Replacement - Rear»(ref-241679-S03806905162006081100000) in Interior Trim.
  1. Remove the left side rear quarter trim panel.
  2. Remove the rear (auxiliary) A/C outlet lower duct bolt (1).
  3. Remove the A/C outlet lower duct (2).
  1. Install the A/C outlet lower duct (2).
  2. Install the rear (auxiliary) A/C outlet lower duct bolt (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the left side rear quarter trim panel.
  1. Remove the left side rear quarter trim panel.
  2. Remove the rear (auxiliary) A/C outlet pillar duct bolts (1).
  3. Remove the A/C outlet pillar duct (2).
  1. Install the A/C outlet pillar duct (2).
  2. Install the rear (auxiliary) A/C outlet pillar duct bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the left side rear quarter trim panel.
  1. Remove the left side rear quarter trim panel.
  2. Remove the rear (auxiliary) A/C outlet pillar duct bolts (1).
  3. Remove the A/C outlet pillar duct (2).
  4. Remove the left side rear quarter trim panel.
  5. Remove the rear (auxiliary) A/C outlet lower duct bolt (1).
  6. Remove the A/C outlet lower duct (2).
  7. Remove the rear (auxiliary) A/C outlet duct bolts (1).
  8. Remove the A/C outlet duct (2).
  1. Install the A/C outlet duct (2).
  2. Install the rear (auxiliary) A/C outlet duct bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the A/C outlet lower duct (2).
  4. Install the rear (auxiliary) A/C outlet lower duct bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
  5. Install the A/C outlet pillar duct (2).
  6. Install the rear (auxiliary) A/C outlet pillar duct bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  7. Install the left side rear quarter trim panel.
  1. Remove the auxiliary HVAC module. Refer to «HVAC Module Replacement - Auxiliary»(ref-241728-S07714973632006081100000) .
  2. Remove the auxiliary heater pipe clamp screw.
  3. Remove the auxiliary heater core mounting screws.
  4. Remove the auxiliary heater core from the HVAC module assembly.
  5. Remove the pipe seal from the auxiliary heater core.
  6. Remove the heater core mounting bracket from the auxiliary heater core.
  1. Install new seals onto the auxiliary heater core.
  2. Install the heater core mounting bracket to the auxiliary heater core.
  3. Install a new pipe seal onto the auxiliary heater core.
  4. Install the auxiliary heater core into the HVAC module assembly.
  5. Install the auxiliary heater core mounting screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  6. Install the auxiliary heater pipe clamp screw. Tighten: Tighten the screw to 1.6 N.m (14 lb in).
  7. Install the auxiliary HVAC module. Refer to «HVAC Module Replacement - Auxiliary»(ref-241728-S07714973632006081100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Remove the left lower quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Left»(ref-241679-S30922318502006081100000) .
  3. Remove the foam wrap from the auxiliary thermal expansion valve (TXV).
  4. Remove the auxiliary TXV line clamp screws.
  5. Remove the auxiliary TXV line clamp from the HVAC module assembly.
  6. Remove the bolt from the auxiliary TXV line block fitting.
  7. Remove the A/C lines from the auxiliary TXV.
  8. Remove and discard the sealing washers.
  9. Cap or tape the A/C lines.
  10. Remove the auxiliary TXV to evaporator core bolts.
  11. Remove the auxiliary TXV from the evaporator core.
  12. Cap or tape off the evaporator core lines.
  13. Remove and discard the sealing washers.
  1. Remove the cap or tape from the evaporator lines.
  2. Install the new sealing washers onto the evaporator lines. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  3. Install the auxiliary TXV to the evaporator core.
  4. Install the auxiliary TXV to the evaporator core mounting bolts. Tighten: Tighten the bolts to 3.5 N.m (31 lb in).
  5. Remove the cap or tape from the A/C lines.
  6. Install the new sealing washers onto the A/C line. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  7. Install the A/C lines to the auxiliary TXV.
  8. Install the auxiliary TXV line block fitting retaining bolt. Tighten: Tighten the nut to 11 N.m (97 lb in).
  9. Install the auxiliary TXV line clamp to the HVAC module assembly.
  10. Install the auxiliary TXV line clamp screw. Tighten: Tighten the screw to 1.6 N.m (14 lb in).
  11. Install a new foam wrap to the auxiliary TXV.
  12. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  13. Leak test the fittings of the component using J 39400-A .
  14. Install the left lower quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Left»(ref-241679-S30922318502006081100000) in Interior Trim.
IMPORTANTCap or tape the open air conditioning (A/C) components immediately in order to prevent system contamination.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  2. Remove the left rear quarter trim panel.
  3. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
  5. Remove the level ride air compressor. Refer to «Air Compressor Replacement»(ref-241717-S04702426332006081100000) in Automatic Level Control.
  6. Remove the auxiliary A/C line block fitting bolt.
  7. Remove the A/C line (1) block fitting.
  8. Remove and discard the sealing washers.
  9. Cap or tape the A/C lines.
  10. Disconnect the auxiliary heater hoses (2) from the heater core pipes using the J 38185 or SA9111E.
  11. Lower the vehicle.
  12. Remove the auxiliary A/C outlet pillar duct bolts (1).
  13. Remove the auxiliary A/C outlet pillar duct (2).
  14. Remove the auxiliary A/C outlet duct bolts (1).
  15. Remove the auxiliary A/C outlet duct (2).
  16. Disconnect the auxiliary blower motor electrical connector.
  17. Disconnect the auxiliary blower motor resistor electrical connector.
  18. Disconnect the auxiliary temperature actuator electrical connector.
  19. Remove the HVAC module assembly bolts and nut.
  20. Remove the left power sliding door (PSD) module from the mounting bracket and reposition aside, if equipped.
  21. Remove the HVAC module assembly from the vehicle.
  22. Remove and discard the HVAC module assembly to body seals.
  1. Install new HVAC module assembly to body seals.
  2. Install the HVAC module assembly to the vehicle.
  3. Install the HVAC module assembly bolts and the nut. Tighten: Tighten the bolts/nut to 10 N.m (89 lb in).
  4. Install the left PSD module to the mounting bracket.
  5. Connect the auxiliary temperature actuator electrical connector.
  6. Connect the electrical connector to the auxiliary blower motor resistor.
  7. Connect the auxiliary blower motor electrical connector.
  8. Install the auxiliary A/C outlet duct (2).
  9. Install the auxiliary A/C outlet duct bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  10. Install the auxiliary A/C outlet pillar duct (2).
  11. Install the auxiliary A/C outlet pillar duct bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  12. Raise and suitably support the vehicle.
  13. Connect the auxiliary heater hoses (2) to the heater core pipes.
  14. Remove the cap or tape from the A/C lines.
  15. Install the new sealing washers onto the A/C line. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  16. Install the auxiliary A/C line (1) block fitting bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  17. Install the level ride air compressor. Refer to «Air Compressor Replacement»(ref-241717-S04702426332006081100000) in Automatic Level Control.
  18. Lower the vehicle.
  19. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
  20. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) .
  21. Leak test the fittings of the component using J 39400-A .
  22. Install the left rear quarter trim panel.
  1. Remove the auxiliary HVAC module assembly. Refer to «HVAC Module Replacement - Auxiliary»(ref-241728-S07714973632006081100000) .
  2. Remove the auxiliary thermal expansion valve (TXV) line clamp screws.
  3. Remove the auxiliary TXV line clamp from the HVAC module assembly.
  4. Remove the TXV insulation.
  5. Remove the bolt from the auxiliary TXV line block fitting.
  6. Disconnect the A/C lines from the auxiliary TXV.
  7. Remove and discard the sealing washers.
  8. Cap or tape the A/C lines.
  9. Remove the auxiliary TXV to auxiliary evaporator core bolts.
  10. Remove the auxiliary TXV from the auxiliary evaporator core.
  11. Remove and discard the sealing washers.
  12. Remove the auxiliary temperature actuator screws.
  13. Remove the auxiliary temperature actuator from the auxiliary HVAC module.
  14. Remove the auxiliary blower motor housing screws.
  15. Remove the auxiliary blower motor housing from the HVAC module.
  16. Remove the auxiliary HVAC module case screws.
  17. Separate the auxiliary HVAC module case halves.
  18. Remove the auxiliary evaporator core from the lower HVAC module case.
  1. If replacing the auxiliary evaporator core add the specified amount of PAG oil directly to the auxiliary evaporator core. Refer to «Refrigerant System Capacities»(ref-241728-S13874285892006081100000) .
  2. Install the auxiliary evaporator core into the lower HVAC module case.
  3. Assemble the auxiliary HVAC module case halves.
  4. Install the auxiliary HVAC module case screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  5. Install the auxiliary blower motor housing to the HVAC module.
  6. Install the auxiliary blower motor housing screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  7. Install the auxiliary temperature actuator to the auxiliary HVAC module.
  8. Install the auxiliary temperature actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  9. Install new sealing washers to the auxiliary evaporator core. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  10. Remove cap or tape from the A/C lines.
  11. Install the auxiliary TXV to the auxiliary evaporator core.
  12. Install the auxiliary TXV to the auxiliary evaporator core mounting bolts. Tighten: Tighten the bolts to 3.5 N.m (31 lb in).
  13. Install new sealing washers onto the auxiliary TXV line block fitting. Refer to «Sealing Washer Replacement»(ref-241728-S11049835292006081100000) .
  14. Connect the auxiliary TXV line block fitting to the auxiliary evaporator core.
  15. Install the auxiliary TXV line block fitting retaining bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
  16. Install the new TXV insulation.
  17. Install the auxiliary TXV line clamp to the HVAC module assembly.
  18. Install the auxiliary TXV line clamp screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  19. Install the auxiliary HVAC module assembly. Refer to «HVAC Module Replacement - Auxiliary»(ref-241728-S07714973632006081100000) .
  20. Leak test the fittings of the component using J 39400-A .
  1. Remove the left rear quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Left»(ref-241679-S30922318502006081100000) .
  2. Remove the auxiliary evaporator pipe clamp screw.
  3. Remove the auxiliary evaporator drain hose from the evaporator clamp.
  4. Remove the evaporator drain hose from the auxiliary evaporator housing.
  1. Install the evaporator drain hose to the auxiliary evaporator housing.
  2. Install the auxiliary evaporator drain hose to the evaporator clamp.
  3. Install the auxiliary evaporator pipe clamp screw. Tighten: Tighten the screw to 1.6 N.m (14 lb in).
  4. Install the left rear quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Left»(ref-241679-S30922318502006081100000) .

More articles — Heating, Ventilation and Air Conditioning