HVAC Systems: Removal & Installation Chrysler Pacifica CS

REMOVAL

Note. The compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement.

Scheme 22

Scheme 23

1. Disconnect and isolate the negative battery cable.
2. Remove the accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-245448-S38168346922006110200000).
3. Raise and support the vehicle.
4. Disconnect the engine wire harness connector from the clutch coil connector located on the top of the A/C compressor.
5. On models with the 3.3L and 3.8L engines, disengage the engine wire harness connector retainer from the bracket located on the top of the A/C compressor.
6. On models with the 2.4L, 2.5L and 2.8L engines, remove all of the compressor mounting bolts except the upper left (rear of the A/C compressor), which should only be loosened. Allow the front (pulley end) of the A/C compressor to tilt downward far enough to access the clutch for removal, then tighten the loosened upper left compressor mounting bolt.
7. On models with the 3.3L and 3.8L engines, remove the two bolts and two nuts that secure the A/C compressor to the engine. Disengage the mounting ear at the front of the A/C compressor from the stud on the engine, allow the front (pulley end) of the A/C compressor to tilt downward far enough to access the clutch for removal, then reinstall and tighten the upper left compressor mounting bolt.
8. Remove the compressor shaft bolt. (Scheme 22) A band-type oil filter wrench or a strap wrench may be used to secure the clutch during bolt removal. 1 - BOLT 2 - COMPRESSOR CLUTCH PLATE
9. Tap the clutch plate lightly with a plastic mallet to release it from the splines on the compressor shaft. Remove the clutch plate and shim(s) from the compressor shaft. see scheme 9 NOTE: Use care not to lose any of the shim(s). CAUTION: Do not pry between the clutch plate unit and the pulley to remove the clutch plate from the compressor shaft as this may damage the clutch plate. 1 - A/C COMPRESSOR SHAFT 2 - CLUTCH PLATE 3 - SHIM
10. Using snap ring pliers (Special Tool C-4574 or equivalent), remove the external snap ring that secures the pulley to the front cover of the A/C compressor, then slide the pulley off of the compressor. (Scheme 23) 1 - SNAP RING 2 - SNAP RING PLIERS 3 - CLUTCH PULLEY AND BEARING
11. Remove the screw that secures the clutch coil wire lead connector bracket and ground clip to the top of the compressor housing.
12. Using snap ring pliers (Special Tool C-4574 or equivalent), remove the external snap ring that secures the clutch coil to the front cover of the compressor housing, then slide the clutch coil off of the A/C compressor. (Scheme 24)

Scheme 24

Scheme 25

1. Align the dowel pin on the back of the clutch coil with the hole in the compressor front cover and position the clutch coil onto the A/C compressor. Be certain that the clutch coil pigtail wires are properly oriented and routed so that they are not pinched between the compressor front cover and the clutch coil. NOTE: A new snap ring must be used to secure the clutch coil to the A/C compressor. The bevel side of the snap ring must face outward.
2. Using snap ring pliers (Special Tool C-4574 or equivalent), install the external snap ring that secures the clutch coil to the front cover of the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or the left of the clutch coil dowel pin location on the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the compressor front cover.
3. Install and securely tighten the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing.
4. Install the pulley onto the front cover of the A/C compressor. If necessary, tap the pulley gently with a block of wood placed on the pulley friction surface. (Scheme 25) CAUTION: Do not mar the friction surfaces of the pulley. 1 - PULLEY AND BEARING 2 - WOOD BLOCK NOTE: A new snap ring must be used to secure the clutch pulley to the A/C compressor. The bevel side of the snap ring must face outward.
5. Using snap ring pliers (Special Tool C-4574 or equivalent), install the external snap ring (bevel side facing outward) that secures the clutch pulley to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.
6. If the original clutch plate and clutch pulley are to be reused, reinstall the original shim(s) on the compressor shaft against the shoulder. If a new clutch plate and/or clutch pulley are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick on the compressor shaft against the shoulder.
7. Install the clutch plate onto the compressor shaft. NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is still correct. Spin the pulley before performing a final check of the air gap.
8. With the clutch plate assembly tight against the shim(s), measure the air gap between the clutch plate and the pulley face with feeler gauges. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained.
9. Install the compressor shaft bolt. Tighten the bolt to 17.5 N.m (155 in. lbs.).
10. On models with the 2.4L, 2.5L and 2.8L engines, loosely install the four bolts that secure the A/C compressor to the mounting bracket on the engine (2.4L), or the cylinder block (2.5L/2.8L). Tighten the bolts to 28 N.m (21 ft. lbs.).
11. On models with the 3.3L and 3.8L engines, loosely install the two bolts and two nuts that secure the A/C compressor to the engine. Tighten each of the fasteners to 54 N.m (40 ft. lbs.) using the following sequence: The upper nut at the front of the compressor. The lower nut at the front of the compressor. The upper bolt at the rear of the compressor. The lower bolt at the rear of the compressor.
12. On models with the 3.3L and 3.8L engines, engage the retainer on the engine wire harness compressor clutch coil take out with the bracket on the top of the A/C compressor.
13. Connect the engine wire harness connector to the A/C compressor clutch coil.
14. Install the accessory drive belt. «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-245448-S15036353902006110200000).
15. Lower the vehicle.
16. Reconnect the negative battery cable.

1. Disconnect and isolate the negative battery cable.
2. Remove the cover from the integrated power module (IPM) located in the engine compartment. (Scheme 26) NOTE: Refer to the fuse and relay map on the inside of the IPM cover for A/C compressor clutch relay location.
3. Remove the A/C compressor clutch relay from the IPM.

Scheme 26

INSTALLATION

Note. Refer to the fuse and relay map on the inside of the integrated power module (IPM) cover for A/C compressor clutch relay location.

1. Position the A/C compressor clutch relay into the receptacle in the IPM.
2. Align the A/C compressor clutch relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated.
3. Install the cover onto the IPM.
4. Reconnect the negative battery cable.

1. Disconnect and isolate the negative battery cable.
2. Remove the center bezel from the instrument panel «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - REMOVAL)»(ref-245423-S18120095492006110200000).
3. Remove the three screws that secure the A/C-heater control to the instrument panel. (Scheme 27)
4. Remove the A/C-heater control from the instrument panel and disconnect the two wire harness connectors from the control.

Scheme 27

1. Position the A/C-heater control to the instrument panel.
2. Connect the two wire harness connectors to the back of the A/C-heater control.
3. Install the A/C-heater control into the instrument panel.
4. Install the three screws that secure the A/C-heater control to the instrument panel. Tighten the screws to 2 N.m (17 in. lbs.).
5. Reconnect the negative battery cable and calibrate the A/C-heater control «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C HEATER CONTROL - STANDARD PROCEDURE -A/C-HEATER CONTROL CALIBRATION)»(ref-245452-S15299216602006110200000) .

Note. It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer.

1. Disconnect and isolate the negative battery cable.
2. Disconnect the wire harness connector from the A/C pressure transducer located on the liquid line. (Scheme 28)
3. Remove the A/C pressure transducer from the fitting on the liquid line and remove and discard the O-ring seal.

Scheme 28

Note. Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor.

1. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
2. Install the A/C pressure transducer onto the liquid line. Tighten the A/C pressure transducer securely.
3. Connect the wire harness connector to the A/C pressure transducer.
4. Reconnect the negative battery cable.

Note. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door.

1. Disconnect and isolate the negative battery cable.
2. Remove the silencer from beneath the driver side end of the instrument panel. Refer to «INSTRUMENT PANEL»(ref-245423-S16928992862006110600000).
3. Disconnect the wire harness connector from the blend door actuator being serviced. (Scheme 29)
4. Remove the two screws that secure the blend door actuator being serviced to the HVAC air distribution housing and remove the actuator.

Scheme 29

1. Position the blend door actuator being serviced onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door linkage.
2. Install the two screws that secure the blend door actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the HVAC wire harness connector to the blend door actuator being serviced.
4. Install the silencer under the driver side end of the instrument panel. Refer to «INSTRUMENT PANEL»(ref-245423-S16928992862006110600000) .
5. Reconnect the negative battery cable and calibrate the A/C-heater control «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C HEATER CONTROL - STANDARD PROCEDURE -A/C-HEATER CONTROL CALIBRATION)»(ref-245452-S15299216602006110200000) .

1. Disconnect and isolate the negative battery cable.
2. Remove the glove box from the instrument panel «(Refer to BODY/INSTRUMENT PANEL/GLOVE BOX - REMOVAL)»(ref-245423-S27842111712006110200000).
3. Disconnect the two wire harness connectors from the front blower motor power module. (Scheme 30)
4. Remove the two screws that secure the front blower motor power module to the front HVAC housing and remove the power module.

Scheme 30

1. Position the front blower motor power module into the front HVAC housing.
2. Install the two screws that secure the front blower motor power module to the front HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the two wire connectors to the front blower motor power module.
4. Install the glove box «(Refer to BODY/INSTRUMENT PANEL/GLOVE BOX - INSTALLATION)»(ref-245423-S33543775612006110200000) .
5. Reconnect the negative battery cable.

1. Disconnect and isolate the negative battery cable.
2. Remove the cover from the integrated power module (IPM) located in the engine compartment. see scheme 23 NOTE: Refer to the fuse and relay map on the IPM cover for front blower motor relay location.
3. Remove the front blower motor relay from the IPM.

Note. Refer to the fuse and relay map on the cover of the integrated power module (IPM) for front blower motor relay location.

1. Position the front blower motor relay to the proper receptacle in the IPM.
2. Align the front blower motor relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated.
3. Install the cover onto the IPM.
4. Reconnect the negative battery cable.

1. Disconnect and isolate the negative battery cable.
2. Remove the glove box from the instrument panel «(Refer to BODY/INSTRUMENT PANEL/GLOVE BOX - REMOVAL)»(ref-245423-S27842111712006110200000).
3. Disconnect the two wire harness connectors from the blower motor resistor. (Scheme 31)
4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor.

Scheme 31

1. Position the blower motor resistor into the HVAC housing.
2. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the two wire connectors to the blower motor resistor.
4. Install the glove box «(Refer to BODY/INSTRUMENT PANEL/GLOVE BOX - INSTALLATION)»(ref-245423-S33543775612006110200000) .
5. Reconnect the negative battery cable.

1. Disconnect and isolate the battery negative cable.
2. Remove the air cleaner housing from the right side of the engine compartment.
3. Remove the temperature sensor retainer from the expansion valve. (Scheme 32)
4. Pull the evaporator temperature sensor away from the expansion valve far enough to access the red release ring on the wiring connector. Push the red ring toward the connector to release the lock and remove the wire harness connector from the evaporator temperature sensor.
5. Remove the evaporator temperature sensor from the engine compartment.

Scheme 32

Note. Any grease removed with the evaporator temperature sensor must be replaced. Failure to do so could result in poor A/C performance.

1. Position the evaporator temperature sensor into the right rear corner of the engine compartment.
2. Reconnect the wire harness connector to the evaporator temperature sensor.
3. Position the evaporator temperature sensor onto the top of the expansion valve with the sensor probe inserted into the well in the expansion valve.
4. Install the temperature sensor retainer.
5. Reinstall the air cleaner housing into the right side of the engine compartment.
6. Reconnect the battery negative cable.
7. Run the HVAC Cool Down test to verify system is operating properly. «(Refer to HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING)»(ref-245452-S19301435982006110200000) .

1. Disconnect and isolate the negative battery cable.
2. Remove the silencer from beneath the driver side end of the instrument panel. (Refer to «INSTRUMENT PANEL»(ref-245423-S16928992862006110600000) ).
3. Disconnect the wire harness connector from the mode door actuator. see scheme 29
4. Remove the two screws that secure the mode door actuator to the HVAC air distribution housing and remove the actuator.

1. Position the mode door actuator onto the HVAC air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage.
2. Install the two screws that secure the mode door actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the wire harness connector to the mode door actuator.
4. Install the silencer under the driver side end of the instrument panel (Refer to «INSTRUMENT PANEL»(ref-245423-S16928992862006110600000) ).
5. Reconnect the negative battery cable and calibrate the A/C-heater control «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C HEATER CONTROL - STANDARD PROCEDURE -A/C-HEATER CONTROL CALIBRATION)»(ref-245452-S15299216602006110200000) .

1. Disconnect and isolate the negative battery cable.
2. Pull the carpet on the passenger side front floor away from the dash panel far enough to access the recirculation door actuator.
3. Disconnect the HVAC wire harness connector from the recirculation door actuator. (Scheme 33)
4. Remove the two screws that secure the recirculation door actuator to the air inlet housing and remove the actuator.

Scheme 33

1. Position the recirculation door actuator onto the air inlet housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the recirculation-air door pivot shaft.
2. Install the two screws that secure the recirculation door actuator to the air inlet housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the HVAC wire harness connector to the recirculation door actuator.
4. Reposition the carpet on the passenger side front floor back up to the dash panel.
5. Reconnect the negative battery cable and calibrate the A/C-heater control «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C HEATER CONTROL - STANDARD PROCEDURE -A/C-HEATER CONTROL CALIBRATION)»(ref-245452-S15299216602006110200000) .

1. Disconnect and isolate the negative battery cable.
2. Remove the cover from the integrated power module (IPM) located in the engine compartment. see scheme 33 NOTE: Refer to the fuse and relay map on the IPM cover for rear blower motor relay location.
3. Remove the rear blower motor relay from the IPM.

Note. Refer to the fuse and relay map on the cover of the integrated power module (IPM) for rear blower motor relay location.

1. Position the rear blower motor relay to the proper receptacle in the IPM.
2. Align the rear blower motor relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated.
3. Install the cover onto the IPM.
4. Reconnect the negative battery cable.

1. Disconnect and isolate the negative battery cable.
2. Remove the control knob from the rear blower motor switch.
3. Using a trim stick C-4755 or equivalent, gently pry the outer perimeter of the rear control panel from the rear of the center floor console.
4. Disconnect the wire harness connector from the rear blower motor switch. (Scheme 34)
5. Remove the two screws that secure the rear blower motor switch to the rear control panel and remove the switch from the panel.

Scheme 34

1. Position the rear blower motor switch onto the rear control panel.
2. Install the two screws that secure the blower motor switch to the rear control panel. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the wire harness connector to the rear blower motor switch.
4. Install the rear control panel to the rear of the center floor console.
5. Install the control knob onto the rear blower motor switch.
6. Reconnect the negative battery cable.

1. Remove the front center floor console cover «(Refer to BODY/INTERIOR/CENTER CONSOLE - REMOVAL)»(ref-245423-S35687059132006110200000).
2. Disconnect and isolate the negative battery cable.
3. Disconnect the body wire harness connector from the rear mode door actuator. (Scheme 35)
4. Remove the two screws that secure the mode door actuator to the rear blower motor housing and remove the actuator.

Scheme 35

1. Position the rear mode door actuator onto the rear blower motor housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage.
2. Install the two screws that secure the rear mode door actuator to the blower motor housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the wire harness connector to the rear mode door actuator.
4. Reconnect the negative battery cable.
5. Install the front center floor console cover «(Refer to BODY/INTERIOR/CENTER CONSOLE - INSTALLATION)»(ref-245423-S27588691282006110200000) .
6. Calibrate the A/C-heater control «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C HEATER CONTROL - STANDARD PROCEDURE -A/C-HEATER CONTROL CALIBRATION)»(ref-245452-S15299216602006110200000) .

1. Remove the rear center console upper cover «(Refer to BODY/INTERIOR/CENTER CONSOLE - REMOVAL)»(ref-245423-S35687059132006110200000).
2. Disconnect and isolate the negative battery cable.
3. Disconnect the body wire harness connector from the rear blower motor power module. (Scheme 36)
4. Disconnect the rear blower motor wire harness connector from the power module.
5. Remove the two screws that secure the power module to the rear blower motor housing.
6. Remove the power module from the blower motor housing.

Scheme 36

1. Position the rear blower motor power module into the rear blower motor housing.
2. Install the two screws that secure the power module to the blower motor housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Reconnect the blower motor wire harness connector to the power module.
4. Reconnect the body wire harness connector to the power module.
5. Reconnect the negative battery cable.
6. Install the front center floor console cover «(Refer to BODY/INTERIOR/CENTER CONSOLE - INSTALLATION)»(ref-245423-S27588691282006110200000) .

1. Locate the air filter door on the bottom of the lower front HVAC housing just outboard of the passenger side of the instrument panel center stack. (Scheme 37)
2. Slide the air filter door latch toward the rear of the vehicle until it engages the opened stop on the door.
3. Pull the air filter door straight downward to disengage it from the air filter opening of the HVAC housing.
4. Use your fingers to reach through the air filter opening of the HVAC housing far enough to grasp the air filter.
5. Pull the air filter straight down and out of the HVAC housing.

Scheme 37

Note. The particulate air filter is labeled with "Airflow" and an arrow to indicate air flow direction through the filter. This arrow should always be oriented towards the center of the vehicle. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design.

1. Install the filter fully upward into the HVAC housing through the air filter opening with the "Airflow" arrow oriented towards the center of the vehicle.
2. With the latch still positioned against its opened stop, install the air filter door onto the lower HVAC housing air filter opening.
3. Slide the air filter door latch toward the front of the vehicle until it contacts the closed stop on the door.

Note. The blower motor is located on the passenger side of the vehicle under the instrument panel. The blower motor can be removed from the vehicle without having to remove the HVAC housing.

Scheme 38

Scheme 39

1. Disconnect and isolate the negative battery cable.
2. Remove the passenger side cowl trim panel «(Refer to BODY/INTERIOR/COWL TRIM - REMOVAL)»(ref-245423-S34691351402006110200000).
3. Pull back the carpet to access the front upper screw that secures the air inlet housing.
4. Remove the recirculation door actuator «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/RECIRCULATION DOOR ACTUATOR - REMOVAL)»(ref-245452-S18372870492006110200000).
5. Remove the recirculation door actuator wire lead from the routing clip located on the lower air inlet housing and position the wire lead aside.
6. Disconnect the blower motor wire lead connector from the blower motor resistor or power module, depending on application.
7. Remove the one screw (from the top) that secures the lower air inlet housing to the upper air inlet housing. (Scheme 38)
8. Remove the four screws (from the bottom) that secure the lower air inlet housing to the upper air inlet housing and remove the lower HVAC housing. 1 - BLOWER MOTOR RESISTOR/POWER MODULE 2 - BLOWER MOTOR WIRE LEAD 3 - LOWER HVAC HOUSING 4 - UPPER AIR INLET HOUSING 5 - UPPER SCREW (1) 6 - LOWER AIR INLET HOUSING 7 - RECIRCULATION DOOR ACTUATOR 8 - ACTUATOR WIRE LEAD 9 - LOWER SCREW (4)
9. Push the rubber blower motor wire lead grommet through the opening in the lower air inlet housing. (Scheme 39)
10. Feed the blower motor wire lead through the opening in the lower air inlet housing and remove the lower air inlet housing from the vehicle. 1 - BLOWER MOTOR WIRE LEAD GROMMET
11. Position the recirculation-air door as necessary to access and remove the three screws that secure the blower motor to the lower half of the HVAC housing.
12. Gently flex the recirculation air door far down enough to remove the blower motor and wheel from the HVAC housing.
13. Remove the blower motor and wheel from the HVAC housing. Note the position of the blower motor mounting tabs. see scheme 47

1. Position the blower motor and wheel to the lower half of the HVAC housing. Align the blower motor mounting tabs to the correct location on the HVAC housing.
2. Gently flex the recirculation-air door far down enough to install the blower motor and wheel into the HVAC housing.
3. Position the recirculation-air door as necessary to install the three screws that secure the blower motor to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
4. Feed the blower motor wire lead through the opening in the lower air inlet housing and seat the rubber grommet into the lower air inlet housing.
5. Position the recirculation-air door pivot into the lower air inlet housing.
6. Install the four screws (from the bottom) that secure the lower air inlet housing to the upper air inlet housing and the lower HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
7. Install the one screw (from the top) that secures the lower air inlet housing to the upper air inlet housing. Tighten the screws to 2 N.m (17 in. lbs.).
8. Connect the blower motor wire lead connector to the blower motor resistor or power module, depending on application.
9. Install the recirculation door actuator wire lead into the routing clip located on the lower air inlet housing.
10. Install the recirculation door actuator «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/RECIRCULATION DOOR ACTUATOR - INSTALLATION)»(ref-245452-S16163684232006110200000) .
11. Reinstall the carpet.
12. Install the passenger side cowl trim panel «(Refer to BODY/INTERIOR/COWL TRIM - INSTALLATION)»(ref-245423-S26095740092006110200000) .
13. Reconnect the negative battery cable.
14. Perform the heater-A/C control calibration procedure «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C-HEATER CONTROL - STANDARD PROCEDURE - HEATER-A/C CONTROL CALIBRATION)»(ref-245452-S15299216602006110200000) .

1. Remove the center console assembly to access the front floor distribution duct «(Refer to BODY/INTERIOR/CENTER CONSOLE - REMOVAL)»(ref-245423-S35687059132006110200000).
2. Remove the screws that secure the floor distribution duct to the bottom of the HVAC housing.
3. Pull the floor distribution duct rearward far enough to disengage the floor distribution duct from the outlet on the bottom of the HVAC housing.
4. Remove the floor distribution duct from the vehicle. (Scheme 40)

Scheme 40

1. Position the floor distribution duct under the instrument panel center stack and engage the center floor distribution duct with the outlet on the bottom of the HVAC housing.
2. Install the floor distribution duct screws. Tighten screws to 2 N.m (17 in. lbs.).
3. Reinstall the center console «(Refer to BODY/INTERIOR/CENTER CONSOLE - INSTALLATION)»(ref-245423-S27588691282006110200000) .

Note. The rear blower motor and blower wheels are serviced only as a balanced unit. If either component is faulty or damaged, the entire blower motor and wheel assembly must be replaced.

Scheme 41

1. Remove the front center floor console cover. «(Refer to BODY/INTERIOR/CENTER CONSOLE - REMOVAL)»(ref-245423-S35687059132006110200000).
2. Disconnect and isolate the negative battery cable.
3. Disconnect the body wire harness connectors from the rear blower motor power module and the rear mode door actuator. (Scheme 41)
4. Remove the body wire harness bracket from the console support bracket.
5. Remove the eight screws and the two console support brackets from the floor console base and duct assembly 1 - SUPPORT BRACKET (FRONT) 2 - POWER MODULE 3 - SCREWS (8) 4 - SCREWS (4) 5 - REAR BLOWER MOTOR HOUSING 6 - REAR MODE DOOR ACTUATOR 7 - SUPPORT BRACKET (REAR)
6. Remove the four screws that secure the rear blower motor housing to the floor console base and duct assembly.
7. Remove the rear blower motor housing and place it on a bench.
8. Disconnect the rear blower motor wire harness connector from the power module.
9. Remove the eleven retaining clips and three screws that secure the housing together.
10. Carefully separate the two halves of the housing.
11. Remove the blower motor wire harness and grommet from the housing and remove the blower motor. (Scheme 42)

Scheme 42

1. Position the rear blower motor into the housing and install the blower motor wire harness and grommet.
2. Assemble the two halves of the rear blower motor housing and install the eleven retaining clips and three screws. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the rear blower motor wire harness connector to the rear blower motor power module.
4. Position the rear blower motor housing into the floor console.
5. Install the four screws that secure the rear blower motor housing to the floor console base. Tighten the screws to 2 N.m (17 in. lbs.).
6. Position the two console support brackets onto the floor console base.
7. Install the eight screws that secure the support brackets to the floor console base. Tighten the screws to 2 N.m (17 in. lbs.).
8. Install the body wire harness bracket onto the console rear support bracket.
9. Connect the body wire harness connectors to the rear blower motor power module and the rear mode door actuator.
10. Reconnect the negative battery cable.
11. Install the front center floor console. «(Refer to BODY/INTERIOR/CENTER CONSOLE - INSTALLATION)»(ref-245423-S27588691282006110200000) .
12. Calibrate the A/C-heater control. «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C HEATER CONTROL - STANDARD PROCEDURE -A/C-HEATER CONTROL CALIBRATION)»(ref-245452-S15299216602006110200000) .

1. Recover the refrigerant from the refrigerant system. «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY»(ref-245452-S36829399792006110200000).
2. Disconnect and isolate the negative battery cable.
3. Remove the radiator fan «(Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL)»(ref-245448-S13296076712006110200000).
4. Remove the nuts that secures the suction and discharge lines to the A/C compressor.
5. Disconnect the suction and discharge lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
6. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.
7. Remove the accessory drive belt (Refer to «COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL»(ref-245448-S38168346922006110200000) ).
8. Disconnect the engine wire harness from the field coil connector located on the top of the A/C compressor. (Scheme 43)
9. Disengage the engine wire harness from the wiring bracket located on the top of the A/C compressor.
10. Remove the four bolts that secure the A/C compressor to the mounting bracket and support the compressor.
11. Raise and support the vehicle.
12. Remove the underside compressor splash shield push pins and the splash shield.
13. Remove the A/C compressor from the compressor mounting bracket.
14. If required, remove the four bolts that secure the compressor mounting bracket to the engine and remove the bracket.

Scheme 43

Note. If a replacement A/C compressor is being installed, be certain to drain and measure the refrigerant oil contained in the old compressor. This will determine how much refrigerant oil the replacement A/C compressor must contain before it is installed. (Refer to HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL) .

Note. The receiver/drier should always be replaced when the A/C compressor is replaced. This will help remove any contaminants including moisture from the system.

1. If removed, position the compressor mounting bracket onto the engine and install the four retaining bolts. Tighten the bolts to 115 N.m (85 ft. lbs.).
2. Position the A/C compressor onto the compressor mounting bracket and support the compressor.
3. Install the underside compressor splash shield and the push-pin retainers.
4. Lower the vehicle.
5. Loosely install the four bolts that secure the A/C compressor to the compressor mounting bracket. Tighten each of the bolts using the following sequence to 33 N.m (25 ft. lbs.). The upper bolt at the front of the compressor. The lower bolt at the front of the compressor. The upper bolt at the rear of the compressor. The lower bolt at the rear of the compressor.
6. Engage the engine wire harness lead to the wiring bracket located on the top of the A/C compressor.
7. Connect the engine wire harness to the field coil connector.
8. Install the accessory drive belt. «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-245448-S15036353902006110200000) .
9. Remove the plugs or tape from the refrigerant line fittings and the compressor ports.
10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and a new gasket onto the suction and discharge line.
11. Connect the suction and discharge lines to the A/C compressor.
12. Install the nuts that secure the suction and discharge lines to the A/C compressor. Tighten the nuts to 23 N.m (17 ft. lbs.).
13. Install the radiator fan «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-245448-S13225941362006110200000) .
14. Connect the negative battery cable.
15. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
16. Charge the refrigerant system. «Refer to REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) .

1. Remove A/C compressor from the compressor mounting bracket and support the compressor «(Refer to HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - REMOVAL)»(ref-245452-S04711928872006110200000). NOTE: It is not necessary to remove A/C compressor from vehicle to remove bracket from engine.
2. Raise and support the vehicle.
3. Remove the underside compressor splash shield push pins and the splash shield.
4. Remove four bolts that secure the compressor mounting bracket to the engine and remove the bracket. (Scheme 44)

Scheme 44

1. Position the compressor mounting bracket to the engine.
2. Install the four bolts that secure the compressor mounting bracket to the engine. Tighten the bolts to 115 N.m (85 ft. lbs.).
3. Position the A/C compressor onto the compressor mounting bracket and support the compressor.
4. Install the underside compressor splash shield and the push-pin retainers.
5. Lower the vehicle.
6. Install the A/C compressor onto the compressor mounting bracket «(Refer to HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION)»(ref-245452-S03559387012006110200000) .

Note. Before removing the A/C condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the A/C condenser and the radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.

Scheme 45

1. Recover the refrigerant from the refrigerant system. «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY»(ref-245452-S36829399792006110200000).
2. Remove the front fascia. «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL)»(ref-245440-S37590734062006110200000).
3. Remove the four radiator sight shield retaining pins and the radiator sight shield.
4. Remove the radiator air seal retaining pins and the air seals. (Scheme 45) 1 - AIR SEAL (RT SIDE SHOWN, LT SIDE SIMILAR) 2 - UPPER RADIATOR CROSSMEMBER 3 - UPPER CONDENSER MOUNTING BOLT (2) 4 - TRANSMISSION FLUID OIL COOLER 5 - A/C CONDENSER 6 - BOLTS (4) 7 - LOWER CONDENSER MOUNT (2) 8 - UPPER AIR SEAL 9 - PUSH PINS (12)
5. Note the hood latch location on the upper radiator crossmember. Mark the location of latch for reinstallation.
6. Remove the two bolts that secure the hood latch to the upper radiator crossmember and position the latch out of the way.
7. Remove the four bolts that secure the transmission fluid oil cooler to the A/C condenser and position the fluid cooler out of the way. «(Refer to COOLING/TRANSMISSION/TRANS COOLER - REMOVAL)»(ref-245448-S27467920342006110200000).
8. Remove the nuts that secure the discharge and liquid lines to the A/C condenser. (Scheme 46)
9. Disconnect the discharge and liquid lines from the A/C condenser and remove the O-ring seals and gaskets.
10. Install plug in, or tape over the opened refrigerant line fittings and the condenser ports.
11. Remove the two bolts that secure the A/C condenser to the radiator.
12. Lift the A/C condenser and disengage the lower condenser mounting brackets from the radiator.
13. Remove the A/C condenser from the engine compartment.

Scheme 46

Note. If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

Note. Be certain that each of the radiator and condenser air seals are reinstalled in their proper locations. These air seals are required in order for the A/C and engine cooling systems to perform as designed.

1. Position the A/C condenser into the engine compartment.
2. Engage the lower condenser mounting brackets to the radiator.
3. Install the two bolts that secure the A/C condenser to the radiator. Tighten the bolts to 5 N.m (45 in. lbs.).
4. Remove the tape or plug from the opened refrigerant line fittings the condenser ports.
5. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge and liquid line fittings.
6. Connect the discharge and liquid lines to the A/C condenser.
7. Install the nuts that secure the discharge and liquid lines to the A/C condenser. Tighten the nuts to 23 N.m (17 ft. lbs.).
8. Position the transmission fluid oil cooler onto the A/C condenser and install the four retaining bolts. Tighten the bolts to 5 N.m (45 in. lbs.).
9. Position the hood latch to the front of the upper radiator crossmember.
10. Loosely install the two bolts that secure the hood latch to the upper radiator crossmember. Check and adjust the hood latch position as required. Tighten the bolts to 14 N.m (123 in. lbs.).
11. Install the radiator air seals and the air seal retaining pins.
12. Install the radiator sight shield and the sight shield retaining pins.
13. Install the front fascia. «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION)»(ref-245440-S02961106272006110200000) .
14. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
15. Charge the refrigerant system. «Refer to REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) .

Note. Before removing the A/C condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the A/C condenser and the radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.

Scheme 47

1. Recover the refrigerant from the refrigerant system. «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY»(ref-245452-S36829399792006110200000).
2. Remove the front fascia. «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL)»(ref-245440-S37590734062006110200000).
3. Remove the four radiator sight shield retaining pins and the radiator sight shield.
4. Remove the radiator air seal retaining pins and the air seals. see scheme 82 1 - AIR SEAL (RT SIDE SHOWN, LT SIDE SIMILAR) 2 - UPPER RADIATOR CROSSMEMBER 3 - UPPER CONDENSER MOUNTING BOLT (2) 4 - TRANSMISSION FLUID OIL COOLER 5 - A/C CONDENSER 6 - BOLTS (4) 7 - LOWER CONDENSER MOUNT (2) 8 - UPPER AIR SEAL 9 - PUSH PINS (12)
5. Remove the nut that secures the A/C discharge line to the A/C condenser. (Scheme 47)
6. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket.
7. Install plug in, or tape over the opened discharge line fitting and the condenser port. 1 - NUT 2 - LIQUID LINE FITTING 3 - CONDENSER OUTLET PORT
8. Remove the nut that secures the A/C discharge line to the A/C compressor. (Scheme 48)
9. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket.
10. Install plug in, or tape over the opened discharge line fitting and the compressor port.
11. Remove the A/C discharge line from the engine compartment.

Scheme 48

1. Position the A/C discharge line into the engine compartment.
2. Remove the tape or plugs from the discharge line fitting and the compressor port.
3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting.
4. Connect the A/C discharge line to the A/C compressor.
5. Install the nut that secures the A/C discharge line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.).
6. Remove the tape or plugs from the discharge line fitting and the condenser port.
7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting.
8. Connect the A/C discharge line to the A/C condenser.
9. Install the nut that secures the A/C discharge line to the A/C condenser. Tighten the nut to 23 N.m (17 ft. lbs.).
10. Install the radiator air seals and the air seal retaining pins.
11. Install the radiator sight shield and the sight shield retaining pins.
12. Install the front fascia. «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION)»(ref-245440-S02961106272006110200000) .
13. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .

1. Remove the HVAC housing. (Scheme 49)«(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - REMOVAL)»(ref-245452-S09911585562006110200000).
2. Disassemble the HVAC housing as necessary to access the A/C evaporator «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - DISASSEMBLY)»(ref-245452-S17839813602006110200000).
3. Open the rubber flange seal and carefully lift the A/C evaporator and insulator out of the lower half of the HVAC housing. NOTE: If the insulator is deformed or damaged, it must be replaced.
4. If required, remove the insulator from the A/C evaporator.

Scheme 49

Note. If the A/C evaporator is being replaced, add 50 milliliters (1.7 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

1. If removed, install the insulator over the A/C evaporator. NOTE: Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and that the insulator and the rubber flange seal are properly positioned.
2. Install the A/C evaporator into the lower half of the HVAC housing and close the rubber flange seal.
3. Assemble the HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - ASSEMBLY)»(ref-245452-S40034392672006110200000) .
4. Install the HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - INSTALLATION)»(ref-245452-S08736913792006110200000) .

1. Recover the refrigerant from the refrigerant system. «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY»(ref-245452-S36829399792006110200000).
2. Disconnect and isolate the negative battery cable.
3. Remove the air cleaner housing and the air inlet tube. Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) for 3.5L or «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) for 3.8L.
4. Remove the drain tube from the right end of the wiper module.
5. Disconnect the wire harness connector from the A/C pressure transducer. (Scheme 50)
6. Remove the screw that secures the liquid line to the receiver/drier outlet port.
7. Disconnect the liquid line from the receiver/drier outlet port and remove and discard the seal.
8. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier outlet port.
9. Remove the nut that secures the suction line and liquid line fittings to the stud on the A/C expansion valve.
10. Disconnect the A/C suction and liquid line fittings from the A/C expansion valve and remove and discard the seals.
11. Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports.
12. Disconnect the HVAC wire harness connector from the evaporator temperature sensor.
13. Remove the two screws that secure the A/C expansion valve to the evaporator tube tapping plate and remove the expansion valve.
14. Remove the seals from the evaporator inlet and outlet tube fittings and discard.
15. Install plugs in, or tape over the opened evaporator inlet and outlet tube fittings and both expansion valve ports.
16. Remove the retaining screw and evaporator temperature sensor from the A/C expansion valve, if required. «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/EVAPORATOR TEMPERATURE SENSOR - REMOVAL)»(ref-245452-S38392920142006110200000).

Scheme 50

Note. Any grease removed with the evaporator temperature sensor must be replaced. Failure to do so could result in poor A/C performance.

1. If removed, install the evaporator temperature sensor and retaining screw onto the A/C expansion valve «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/EVAPORATOR TEMPERATURE SENSOR - INSTALLATION)»(ref-245452-S05409178272006110200000) .
2. Remove the tape or plugs from the evaporator inlet and outlet tube fittings and both ports on the back of the A/C expansion valve.
3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator inlet and outlet tube fittings.
4. Position the A/C expansion valve onto the evaporator inlet and outlet tube fittings.
5. Install the two screws that secure the A/C expansion valve to the evaporator tube tapping plate plate. Tighten the screws to 11 N.m (97 in. lbs.).
6. Connect the HVAC wire harness connector to the evaporator temperature sensor.
7. Remove the tape or plugs from the front liquid line rear section and suction line fittings for the expansion valve and both ports on the front of the expansion valve.
8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the front liquid line rear section and suction line fittings for the expansion valve.
9. Connect the A/C liquid and suction lines to the expansion valve.
10. Install the nut that secures the A/C liquid and suction lines to the expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
11. Remove the tape or plugs from the liquid line rear section fitting and the receiver/drier outlet port.
12. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
13. Connect the liquid line fitting to the receiver/drier outlet port.
14. Install the screw that secures the liquid line fitting to the receiver/drier. Tighten the screw to 11 N.m (97 in. lbs.).
15. Connect the wire harness connector to the A/C pressure transducer.
16. Install the drain tube to the wiper module.
17. Install the air cleaner housing and air inlet tube. Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) for 3.5L or «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) for 3.8L.
18. Reconnect the negative battery cable.
19. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
20. Charge the refrigerant system. «Refer to REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) .

Note. The heater inlet hose is constructed from formed steel tubing and rubber hoses. Depending on application, the ends are secured to the heater core, engine oil cooler or the engine by spring tension clamps.

1. Drain the engine cooling system. «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN)»(ref-245448-S20805593812006110200000).
2. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. (Scheme 51) CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak.
3. Disconnect each hose end by carefully twisting the hose back and forth on the tube, while gently pulling it away from the end of the tube. NOTE: Replacement of the heater inlet tube will be required if the hose ends are cut for removal.
4. If necessary, carefully cut the hose end and peel the hose off of the tube.
5. Remove the two heater inlet tube retaining bolts and remove the inlet tube.

Scheme 51

1. Position the heater inlet tube into the engine compartment and install the two heater inlet tube retaining bolts. Tighten the bolts to 10 N.m (89 in. lbs.).
2. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when install the heater inlet hose. Excessive pressure may damage or deform the heater tubes or connections, causing an engine coolant leak.
3. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube end.
4. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed.
5. Refill the engine cooling system. «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-245448-S20805593812006110200000) .

Note. The heater return tube is constructed from formed steel tubing and rubber hoses. Depending on application, the ends are secured to the heater core, engine oil cooler or the engine by spring tension clamps.

1. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN)»(ref-245448-S20805593812006110200000).
2. Using spring tension clamp pliers, compress and slide the clamps off of each end of the heater return hose. (Scheme 52) CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak.
3. Disconnect each hose end by carefully twisting the hose back and forth on the tube, while gently pulling it away from the end of the tube. NOTE: Replacement of the heater return hose will be required if the hose ends are cut for removal.
4. If necessary, carefully cut the hose end and peel the hose off of the tube.

Scheme 52

1. Using spring tension clamp pliers, compress and slide the clamp away from the end of the heater return hose. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when install the heater return hose. Excessive pressure may damage or deform the heater tubes or connections, causing an engine coolant leak.
2. Install each hose end by carefully twisting the hose back and forth while gently pushing it onto the tube.
3. Using spring tension clamp pliers, compress and slide the clamps onto each end of the heater return hose.
4. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000) .

Note. The A/C liquid line is serviced in two sections. The front section connects between the A/C condenser and the receiver/drier and includes the high side service port. The rear section connects between the receiver/drier and the A/C expansion valve and includes the fitting for the A/C pressure transducer.

Scheme 53

1. Recover the refrigerant from the refrigerant system. «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY»(ref-245452-S36829399792006110200000).
2. Disconnect and isolate the negative battery cable.
3. Remove the air cleaner housing. Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) for 3.5L or «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) for 3.8L.
4. Remove the front fascia. «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL)»(ref-245440-S37590734062006110200000).
5. Remove the four radiator sight shield retaining pins and the radiator sight shield.
6. Remove the right side radiator air seal retaining pins and the air seal. see scheme 95 1 - AIR SEAL (RT SIDE SHOWN, LT SIDE SIMILAR) 2 - UPPER RADIATOR CROSSMEMBER 3 - UPPER CONDENSER MOUNTING BOLT (2) 4 - TRANSMISSION FLUID OIL COOLER 5 - A/C CONDENSER 6 - BOLTS (4) 7 - LOWER CONDENSER MOUNT (2) 8 - UPPER AIR SEAL 9 - PUSH PINS (12)
7. Remove the nut that secures the A/C liquid line to the A/C condenser. (Scheme 53)
8. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket.
9. Install plug in, or tape over the opened liquid line fitting and the condenser port. 1 - NUT 2 - LIQUID LINE FITTING 2 - CONDENSER OUTLET PORT
10. Disengage the refrigerant line routing clip located on top of the right frame rail. (Scheme 54)
11. Remove the bolt that secures the front section of the A/C liquid line to the receiver/drier.
12. Disconnect the front section of the A/C liquid line from the receiver/drier and remove and discard the O-ring seal.
13. Install plug in, or tape over the opened liquid line fitting and the receiver/drier port.
14. Remove the front section of the A/C liquid line from the engine compartment.

Scheme 54

Note. The A/C liquid line is serviced in two sections. The front section connects between the A/C condenser and the receiver/drier and includes the high side service port. The rear section connects between the receiver/drier and the A/C expansion valve and includes the fitting for the A/C pressure transducer.

1. Recover the refrigerant from the refrigerant system. «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY»(ref-245452-S36829399792006110200000).
2. Remove the air cleaner housing. Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) for 3.5L or «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) for 3.8L.
3. Remove the bolts that secures the front and rear sections of the A/C liquid line to the receiver/drier. (Scheme 55)
4. Disconnect the A/C liquid lines from the receiver/drier and remove and discard the O-ring seals.
5. Install a plug in, or tape over the opened liquid line fittings and the receiver/drier ports.
6. Remove the two nuts that secure the receiver/drier to the right strut tower and remove the receiver/drier.

Scheme 55

Note. If the receiver/drier is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

1. Position the receiver/drier onto the weld studs on the right strut tower.
2. Install the two nuts that secure the receiver/drier to the right strut tower. Tighten the nuts to 10 N.m (89 in. lbs.).
3. Remove the tape or plugs from the liquid line fittings and the receiver/drier ports.
4. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the liquid line fittings.
5. Connect the front and rear sections of the A/C liquid line to the receiver/drier.
6. Install the bolts that secures the A/C liquid lines to the receiver/drier. Tighten the bolts to 11 N.m (100 in. lbs.).
7. Install the air cleaner housing. Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) for 3.5L or «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) for 3.8L.
8. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
9. Charge the refrigerant system. «Refer to REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) .

1. Remove the protective caps from the low and high side service ports. (Scheme 56)
2. Recover the refrigerant from the refrigerant system. «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY»(ref-245452-S36829399792006110200000). CAUTION: Only the low side service port valve core can be replaced. Do not attempt to replace the valve core for the high side service port. If the high side service port valve core requires service, replacement of the A/C liquid line is required.
3. Using a standard Schrader-type valve core tool, remove the valve core from the low side service port only.
4. Install a plug in or tape over the opened low side service port.

Scheme 56

1. Lubricate the A/C service port valve core with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
2. Remove the tape or plug from the low side service port. CAUTION: Only the low side service port valve core can be replaced. Do not attempt to replace the valve core for the high side service port. If the high side service port valve core requires service, replacement of the A/C liquid line is required.
3. Using a standard Schrader-type valve core tool, install and tighten the replacement valve core into the low side service port. CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters.
4. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
5. Charge the refrigerant system. «Refer to REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) .
6. Install the protective caps onto the A/C service ports.

Note. The A/C suction line includes the low side service port located on the section of the line near the A/C expansion valve.

1. Recover the refrigerant from the refrigerant system. «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY»(ref-245452-S36829399792006110200000).
2. Disconnect and isolate the negative battery cable.
3. Remove the air cleaner housing and the air inlet tube. Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) for 3.5L or «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) for 3.8L.
4. Remove the drain tube from the right end of the wiper module.
5. Remove the radiator fan «(Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL)»(ref-245448-S13296076712006110200000).
6. Remove the nut that secures the A/C suction line to the A/C compressor. see scheme 103
7. Disconnect the A/C suction line from the A/C compressor and remove and discard the O-ring seal and gasket.
8. Install a plug in, or tape over the opened suction line fitting and the compressor port. 1 - A/C SUCTION LINE 2 - NUT 3 - A/C COMPRESSOR 4 - NUT 5 - A/C DISCHARGE LINE
9. Disengage the suction line from the routing clip located on top of the right frame rail. (Scheme 57)
10. Remove the nut that secures the suction and liquid lines to the A/C expansion valve.
11. Disconnect the suction and liquid lines from the A/C expansion valve and remove and discard the O-ring seals.
12. Install a plug in, or tape over the opened suction and liquid line fittings and expansion valve ports.
13. Remove the A/C suction line from the engine compartment.

Scheme 57

1. Position the A/C suction line into the engine compartment.
2. Remove the tape or plugs from the suction and liquid line fittings and expansion valve ports.
3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction and liquid line fittings.
4. Connect the suction and liquid lines to the A/C expansion valve.
5. Install the nut that secures the suction and liquid lines to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
6. Engage the suction line to the routing clip located on top of the right frame rail.
7. Remove the tape or plugs from the suction line fitting and compressor port.
8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the suction line fitting.
9. Install the A/C suction line on to the A/C compressor.
10. Install the nut that secures the A/C suction line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.).
11. Install the radiator fan «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-245448-S13225941362006110200000) .
12. Install the drain tube to the wiper module.
13. Install the air cleaner housing and air inlet tube. Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) for 3.5L or «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) for 3.8L.
14. Reconnect the negative battery cable.
15. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
16. Charge the refrigerant system. «Refer to REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) .