HVAC Systems: Removal & Installation Dodge Caravan IV

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 29

Scheme 30

1. Disconnect and isolate the negative battery cable.
2. Remove the accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-248908-S35636680612007022700000).
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 29) 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 6 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 30) 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 31)

Scheme 31

Scheme 32

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 32) 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-248908-S25700648452007022700000).
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 33) 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 33

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 and place it on a workbench «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - REMOVAL)»(ref-248887-S29709799012007022700000).
3. If the vehicle is equipped with the automatic temperature control (ATC) heating-A/C system, disconnect the infrared sensor connector from the back of the A/C-heater control. (Scheme 34)
4. Remove the six screws that secure the A/C-heater control to the back of the instrument panel center bezel and remove the control.

Scheme 34

1. Position the A/C-heater control into the instrument panel center bezel.
2. Install the six screws that secure the A/C-heater control to the instrument panel center bezel. Tighten the screws to 2 N.m (17 in. lbs.).
3. If the vehicle is equipped with the ATC heating-A/C system, connect the infrared sensor connector to A/C-heater control.
4. Install the center bezel onto the instrument panel «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - INSTALLATION)»(ref-248887-S18476627072007022700000) .
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-248916-S29538611692007022700000) .

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 35)
3. Remove the A/C pressure transducer from the fitting on the liquid line and remove and discard the O-ring seal.

Scheme 35

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 single zone heater-A/C system is equipped with a single blend door actuator. 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-248887-S28235020892007030500000) ).
3. Disconnect the wire harness connector from the blend door actuator being serviced. (Scheme 36)
4. Remove the two screws that secure the blend door actuator being serviced to the HVAC air distribution housing and remove the actuator.

Scheme 36

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 being serviced 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-248887-S28235020892007030500000) ).
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-248916-S29538611692007022700000) .

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-248887-S39359986592007022700000).
3. Disconnect the two wire harness connectors from the front blower motor power module. (Scheme 37)
4. Remove the two screws that secure the front blower motor power module to the front HVAC housing and remove the power module.

Scheme 37

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-248887-S07991811432007022700000) .
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. (Scheme 38) 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.

Scheme 38

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-248887-S39359986592007022700000).
3. Disconnect the two wire harness connectors from the front blower motor resistor. (Scheme 39)
4. Remove the two screws that secure the front blower motor resistor to the front HVAC housing and remove the resistor.

Scheme 39

1. Position the front blower motor resistor into the front HVAC housing.
2. Install the two screws that secure the front blower motor resistor 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 resistor.
4. Install the glove box «(Refer to BODY/INSTRUMENT PANEL/GLOVE BOX - INSTALLATION)»(ref-248887-S07991811432007022700000) .
5. Reconnect the negative battery cable.

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-248887-S28235020892007030500000) ).
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-248887-S28235020892007030500000) ).
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-248916-S29538611692007022700000) .

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 40)
4. Remove the two screws that secure the recirculation door actuator to the air inlet housing and remove the actuator.

Scheme 40

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-248916-S29538611692007022700000) .

1. If required, position the rear A/C-heater control onto the rear A/C- heater control housing or bezel (depending on application).
2. Install the three screws that secure the rear A/C-heater control to the housing or bezel. Tighten the screws to 2 N.m (17 in. lbs.).
3. Position the rear A/C-heater control to the headliner or overhead rail (depending on application) and connect the wire harness connector(s) to the rear of the control. If
4. If headliner mounted, insert the locator tabs on the back of the rear A/C-heater control bezel over the forward edge of the opening in the headliner and using hand pressure, push the rear A/C-heater control bezel into the headliner until the two retaining clips fully seat.
5. If overhead rail mounted, position the top of the rear A/C-heater control housing over the overhead rails and using hand pressure, push the rear A/C-heater control housing onto the overhead rails until the retaining clips fully seat.
6. Reconnect the negative battery cable.
7. Using the DRB-III® scan tool, reset the Rear Temperature Selector calibration values.
8. Verify that the Actuator Calibration of the Front Control has passed. If an Actuator Calibration has not passed correct any errors before proceeding further.
9. Rotate the Rear Temperature Selector counter clockwise to the Cold Position, allow the Selector to remain in the Cold Position for 5 seconds.
10. Rotate the Rear Temperature Selector Clockwise to the Hot Position, allow the Selector to remain in the Cold Position for 5 seconds.
11. Calibration is now complete.

1. Disconnect and isolate the negative battery cable.
2. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL)»(ref-248887-S07029878172007022700000).
3. Remove the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel.
4. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar.
5. Remove the screw that secures the front of the rear HVAC housing to the right quarter inner panel.
6. Carefully pull the top of the rear HVAC housing away from the right quarter inner panel far enough to reach between the rear HVAC housing and the quarter inner panel to access the rear blend door actuator. (Scheme 41)
7. Remove the two screws that secure the rear blend door actuator to the rear HVAC housing.
8. Pull the rear blend door actuator away from the rear HVAC housing far enough to disengage the actuator output shaft from the rear blend door pivot.
9. Raise the rear blend door actuator far enough to access and disconnect the rear HVAC wire harness connector from the actuator.
10. Remove the rear blend door actuator from between the rear HVAC housing and the quarter inner panel.

Scheme 41

1. Position the rear blend door actuator between the rear HVAC housing and the quarter inner panel.
2. Connect the rear HVAC wire harness connector to the rear blend door actuator.
3. Position the rear blend door actuator onto the rear HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door pivot.
4. Install the two screws that secure the rear blend door actuator to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
5. Push the top of the rear HVAC housing back into position against the right quarter inner panel.
6. Install the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Tighten the screw to 11 N.m (97 in. lbs.).
7. Install the screw that secures the back of the rear HVAC housing to the right D-pillar. Tighten the screw to 11 N.m (97 in. lbs.).
8. Install the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. Tighten the screws to 2 N.m (17 in. lbs.).
9. Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION)»(ref-248887-S20438406012007022700000) .
10. 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-248916-S29538611692007022700000) .

1. Disconnect and isolate the negative battery cable.
2. Remove the cover from the integrated power module (IPM). (Scheme 42) 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.

Scheme 42

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 right quarter trim panel and right D-pillar trim panel from the quarter inner panel «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL)»(ref-248887-S07029878172007022700000)
3. Disconnect the rear HVAC wire harness connector from the rear blower motor resistor. (Scheme 43)
4. Remove the two screws that secure the rear blower motor resistor to the rear HVAC housing and remove the resistor.

Scheme 43

1. Position the rear blower motor resistor into the rear HVAC housing.
2. Install the two screws that secure the rear blower motor resistor to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the rear HVAC wire harness connector to the rear blower motor resistor.
4. Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION)»(ref-248887-S20438406012007022700000) .
5. Reconnect the negative battery cable.

1. Disconnect and isolate the battery negative cable.
2. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL)»(ref-248887-S07029878172007022700000).
3. Remove the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel.
4. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar.
5. Remove the screw that secures the front of the rear HVAC housing to the right quarter inner panel.
6. Carefully pull the top of the rear HVAC housing away from the right quarter inner panel far enough to reach between the rear HVAC housing and the quarter inner panel to access the rear mode door actuator. see scheme 43
7. Remove the two screws that secure the mode door actuator to the rear HVAC housing.
8. Pull the mode door actuator away from the rear HVAC housing far enough to disengage the actuator output shaft from the mode door linkage.
9. Raise the mode door actuator far enough to access and disconnect the rear HVAC wire harness connector from the actuator
10. Remove the rear mode door actuator from between the rear HVAC housing and the quarter inner panel.

1. Position the mode door actuator between the rear HVAC housing and the quarter inner panel.
2. Reconnect the rear HVAC wire harness connector to the rear mode door actuator.
3. Position the rear mode door actuator onto the rear HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage.
4. Install the two screws that secure the rear mode door actuator to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
5. Push the top of the rear HVAC housing back into position against the right quarter inner panel.
6. Install the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Tighten the screw to 11 N.m (97 in. lbs.).
7. Install the screw that secures the back of the rear HVAC housing to the right D-pillar. Tighten the screw to 11 N.m (97 in. lbs.).
8. Install the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. Tighten the screws to 2 N.m (17 in. lbs.).
9. Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION)»(ref-248887-S20438406012007022700000) .
10. Reconnect the battery negative cable.
11. 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-248916-S29538611692007022700000) .

1. Disconnect and isolate the negative battery cable.
2. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL)»(ref-248887-S07029878172007022700000).
3. Disconnect the rear HVAC wire harness connector from the rear blower motor power module. (Scheme 44)
4. Disconnect the rear blower motor wire harness connector from the rear blower motor power module.
5. Remove the two screws that secure the rear blower motor power module to the rear HVAC housing and remove the power module.

Scheme 44

1. Position the rear blower motor power module into the rear HVAC housing.
2. Install the two screws that secure the rear blower motor power module to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the rear blower motor wire harness to the rear blower motor power module.
4. Connect the rear HVAC wire harness connector to the rear blower motor power module.
5. Install the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION)»(ref-248887-S20438406012007022700000) .
6. Reconnect the negative battery cable.

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 45)
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 45

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 46

Scheme 47

1. Disconnect and isolate the negative battery cable.
2. Remove the passenger side cowl trim panel «(Refer to BODY/INTERIOR/COWL TRIM - REMOVAL)»(ref-248887-S26680880802007022700000).
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-248916-S36364959232007022700000).
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 46)
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 47)
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 54

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-248916-S33536297962007022700000) .
11. Reinstall the carpet.
12. Install the passenger side cowl trim panel «(Refer to BODY/INTERIOR/COWL TRIM - INSTALLATION)»(ref-248887-S20444721222007022700000) .
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-248916-S29538611692007022700000) .

1. Roll back the carpet on the front floor from under the instrument panel toward the rear of the vehicle «(Refer to BODY/INTERIOR/CARPETS AND FLOOR MATS - REMOVAL)»(ref-248887-S04621541692007022700000).
2. Lift the center floor distribution duct upward far enough to disengage its locator hole from the weld stud on the front floor panel. (Scheme 48)
3. Pull the center floor distribution duct rearward and disengage it from the floor outlet of the front HVAC housing.
4. Disassemble the right and/or left floor distribution ducts from the center floor distribution duct as required.

Scheme 48

1. Install the right and/or left floor distribution duct onto the center floor distribution duct as required.
2. Position the center floor distribution duct under the instrument panel center stack and engage it to the floor outlet of the front HVAC housing.
3. Align the locator hole on the center floor distribution duct with the weld stud on the front floor panel and install the distribution duct onto the weld stud.
4. Install the carpet onto the front floor panel and under the instrument panel «(Refer to BODY/INTERIOR/CARPETS AND FLOOR MATS - INSTALLATION)»(ref-248887-S21600061842007022700000) .

1. Using a trim stick C-4755 or equivalent, disengage the thumb wheel end of the overhead air outlet from the pivot pin in the headliner bezel. (Scheme 49)
2. Disengage the opposite end of the overhead air outlet from the pivot pin in the headliner bezel and remove the air outlet.

Scheme 49

1. Position the overhead air outlet into the opening in the headliner bezel.
2. Engage the non-thumb wheel end of the overhead air outlet onto the pivot pin in the headliner bezel.
3. Using hand pressure, push the thumb wheel end of the overhead air outlet onto the pivot pin until fully engaged.

1. Remove the trim panels from the inner right quarter panel and the right D-pillar «(Refer to BODY/INTERIOR/RIGHT QUARTER TRIM PANEL - REMOVAL)»(ref-248887-S07029878172007022700000).
2. Slide the rear distribution duct upwards and disengage it from the outlet located at the top of the rear HVAC housing. (Scheme 50)
3. While pulling the lower end of the rear distribution duct away from the rear HVAC housing, disengage the upper end of the distribution duct from the headliner duct and remove the duct.

Scheme 50

1. Position the upper end of the rear distribution duct to the headliner duct.
2. Install the upper end of the rear distribution duct onto the headliner duct and align the lower end of the duct with the outlet at the top of the rear HVAC housing.
3. Slide the rear distribution duct downward and engage it onto the outlet located at the top of the rear HVAC housing.
4. Install the trim panels onto the inner right quarter panel and the right D-pillar «(Refer to BODY/INTERIOR/RIGHT QUARTER TRIM PANEL - INSTALLATION)»(ref-248887-S20438406012007022700000) .

1. Remove the rear HVAC housing and place it on a workbench «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/HVAC HOUSING - REMOVAL)»(ref-248916-S05946612392007022700000). NOTE: On the manual temperature control (MTC) heating-A/C system, the rear blower motor wire harness is connected to the rear HVAC wire harness. On the automatic temperature control (ATC) heating-A/C system, the rear blower motor wire harness is connected to the rear blower motor power module.
2. Disconnect the wire harness connector for the rear blower motor. (Scheme 51)
3. Remove the three screws that secure the rear blower motor to the outboard side of the rear HVAC housing and remove the blower motor.

Scheme 51

1. Position the rear blower motor onto the rear HVAC housing.
2. Install the three screws that secure the rear blower motor to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). NOTE: On the manual temperature control (MTC) heating-A/C system, the rear blower motor wire harness is connected to the rear HVAC wire harness. On the automatic temperature control (ATC) heating-A/C system, the rear blower motor wire harness is connected to the rear blower motor power module.
3. Connect the wire harness connector for the rear blower motor.
4. Install the rear HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/HVAC HOUSING - INSTALLATION)»(ref-248916-S39888388142007022700000) .

Note. The rear HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator and the mode/blend-air door.

Scheme 52

Scheme 53

Scheme 54

1. Recover the refrigerant from the refrigerant system. (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) )
2. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN)»(ref-248908-S09724997062007022700000).
3. Disconnect and isolate the negative battery cable.
4. Raise and support the vehicle.
5. Remove the nut that secures the underbody refrigerant line sealing plate to the rear evaporator extension line tapping plate that extends through the rear floor panel behind the right rear wheel housing. (Scheme 52)and (Scheme 53).
6. Disconnect the underbody refrigerant lines from the rear evaporator extension line tapping plate and remove and discard the O-ring seals.
7. Install plugs in, or tape over the opened underbody refrigerant line fittings and the evaporator extension line sealing plate ports. 1 - UNDERBODY LIQUID LINE 2 - NUT 3 - SEALING PLATE 4 - UNDERBODY SUCTION LINE 5 - EXTENSION LINE TAPPING PLATE 1 - UNDERBODY LIQUID LINE 2 - BOLT 3 - EXTENSION LINE TAPPING PLATE 4 - UNDERBODY SUCTION LINE 5 - SEALING PLATE
8. Remove the nuts from the mounting studs that secure the rear HVAC housing to the rear floor panel behind the right rear wheel housing. (Scheme 54) 1 - REAR HVAC HOUSING MOUNTING STUDS
9. Lower the vehicle.
10. Remove the trim panels from the inner right quarter panel and the right D-pillar «(Refer to BODY/INTERIOR/RIGHT QUARTER TRIM PANEL - REMOVAL)»(ref-248887-S07029878172007022700000).
11. Remove the rear distribution duct from the rear HVAC housing and the rear headliner duct «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR OUTLETS - REMOVAL)»(ref-248916-S28778870452007022700000).
12. Disconnect the body wire harness connector for the rear HVAC housing from the rear HVAC wire harness connector located near the A/C expansion valve.
13. Remove the two screws that secure the top of the quarter trim panel attaching bracket to the inner quarter panel.
14. Remove the two screws that secure the bottom of the quarter trim panel attaching bracket to the rear HVAC housing.
15. Remove the rear floor heat duct from the inner right quarter panel «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/REAR FLOOR HEAT DUCT - REMOVAL)»(ref-248916-S36663927452007022700000). NOTE: Use absorbent toweling to clean up any engine coolant spills.
16. Disconnect the heater hoses at the rear heater core «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER HOSE - REMOVAL)»(ref-248916-S20761806192007022700000).
17. Install plugs in, or tape over the opened heater core fittings and both heater hoses.
18. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar. (Scheme 55)
19. Remove the screw that secures the front of the rear HVAC housing to the inner right quarter panel.
20. Lift the rear HVAC housing up far enough for the lower mounting studs and the evaporator extension lines to clear the mounting holes in the rear floor panel and remove the housing.

Scheme 55

Note. If the rear heater core or the rear HVAC housing have been removed from the vehicle for service, the rear heater core should be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings (Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER CORE - STANDARD PROCEDURE - REAR HEATER CORE FILLING) .

1. Position the rear HVAC housing into the vehicle with the evaporator extension line sealing plate inserted into the opening in the rear floor panel behind the right rear wheel house.
2. Align the rear HVAC housing lower mounting studs with the holes in the rear floor panel and lower the rear HVAC housing to the floor.
3. Install the screw that secures the front of the rear HVAC housing to the inner right quarter panel. Tighten the screw to 11 N.m (97 in. lbs.).
4. Install the screw that secures the back of the rear HVAC housing to the right D-pillar. Tighten the screw to 11 N.m (97 in. lbs.).
5. Remove the plugs or tape from both heater core fittings and both heater hoses.
6. Pre-fill the rear heater core «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER CORE - STANDARD PROCEDURE - REAR HEATER CORE FILLING)»(ref-248916-S14814004262007022700000) .
7. Connect the heater hoses to the rear heater core «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER HOSE - INSTALLATION)»(ref-248916-S28977550362007022700000) .
8. Install the rear floor heat duct onto the inner right quarter panel «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/REAR FLOOR HEAT DUCT - INSTALLATION)»(ref-248916-S40770519802007022700000) .
9. Install the two screws that secure the bottom of the quarter trim panel attaching bracket to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
10. Install and tighten the two screws that secure the top of the quarter trim panel attaching bracket to the inner quarter panel.
11. Connect the wire harness connector to the rear HVAC wire harness connector.
12. Install the rear distribution duct onto the rear HVAC housing and the rear headliner duct «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR OUTLETS - INSTALLATION)»(ref-248916-S29731571182007022700000) .
13. Install the trim panels onto the right inner quarter panel and right D-pillar «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION)»(ref-248887-S20438406012007022700000) .
14. Raise and support the vehicle.
15. Install the three nuts that secure the rear HVAC housing mounting studs to the rear floor panel behind the right rear wheel housing. Tighten the nuts to 9 N.m (80 in. lbs.).
16. Remove the tape or plugs from the underbody refrigerant line fittings and both ports in the rear evaporator extension line sealing plate.
17. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the underbody refrigerant line fittings.
18. Connect the underbody refrigerant line sealing plate to the evaporator extension line tapping plate.
19. Install the nut that secures the underbody refrigerant line sealing plate to the evaporator extension line tapping plate. Tighten the nut to 23 N.m (17 ft. lbs.).
20. Lower the vehicle.
21. Reconnect the negative battery cable.
22. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-248908-S09724997062007022700000) .
23. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
24. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).
25. 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-248916-S29538611692007022700000) .

1. Remove the trim panel from the right inner quarter panel «(Refer to BODY/INTERIOR/RIGHT QUARTER TRIM PANEL - REMOVAL)»(ref-248887-S07029878172007022700000).
2. Remove the two screws that secure the rear floor heat duct to the right inner quarter panel. (Scheme 56)
3. Slide the rear floor heat duct forward to disengage it from the rear HVAC housing and remove the duct.

Scheme 56

1. Position the rear floor heat duct to rear HVAC housing.
2. Slide the rear floor heat duct rearward to engage it to the rear HVAC housing.
3. Install the two screws that secure the rear floor heat duct to the right inner quarter panel. Tighten the screws to 2 N.m (17 in. lbs.).
4. Install the trim panel onto the right inner quarter panel «(Refer to BODY/INTERIOR/RIGHT QUARTER TRIM PANEL - INSTALLATION)»(ref-248887-S20438406012007022700000) .

Scheme 57

1. Recover the refrigerant from the refrigerant system. (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Remove the right headlamp unit «(Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT - REMOVAL)»(ref-248898-S19697015862007022700000).
3. Remove the nut that secures the A/C discharge line to the right end of the A/C condenser. (Scheme 57)
4. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket.
5. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port. 1 - A/C CONDENSER 2 - A/C DISCHARGE LINE 3 - A/C LIQUID LINE 4 - NUT (2)
6. Raise and support the vehicle.
7. Remove the nut that secures the A/C discharge line to the A/C compressor. (Scheme 58)
8. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket.
9. Install plugs in, or tape over the opened discharge line fitting and the compressor discharge port.
10. Remove the A/C discharge line from the engine compartment.

Scheme 58

1. Position the A/C discharge line into the engine compartment.
2. Remove the tape or plugs from the compressor discharge port and the discharge line fitting.
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. Install 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. Lower the vehicle.
7. Remove the tape or plugs from the condenser inlet port and the discharge line fitting.
8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting.
9. Install the A/C discharge line to the A/C condenser.
10. 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.).
11. Install the right headlamp unit «(Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT - INSTALLATION)»(ref-248898-S35521518202007022700000) .
12. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
13. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

1. Remove the front HVAC housing. (Scheme 59)«(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - REMOVAL)»(ref-248916-S05946612392007022700000).
2. Disassemble the front HVAC housing as necessary to access the front A/C evaporator «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - DISASSEMBLY)»(ref-248916-S10555908352007022700000).
3. Open the rubber flange seal and carefully lift the front A/C evaporator and insulator out of the lower half of the front HVAC housing. NOTE: If the insulator is deformed or damaged, it must be replaced.
4. If required, remove the insulator from the front A/C evaporator.

Scheme 59

Note. If the front 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 front A/C evaporator. NOTE: Make sure that the evaporator drain within the front HVAC housing is clean and unrestricted and that the insulator and the rubber flange seal are properly positioned.
2. Install the front A/C evaporator into the lower half of the front HVAC housing and close the rubber flange seal.
3. Assemble the front HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - ASSEMBLY)»(ref-248916-S34272711492007022700000) .
4. Install the front HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - INSTALLATION)»(ref-248916-S39888388142007022700000) .

1. Recover the refrigerant from the refrigerant system. (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Disconnect and isolate the negative battery cable.
3. Remove the air cleaner housing and the air inlet tube «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(ref-248909-S02114513502007022700000) «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(ref-248910-S06389018822007022700000).
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 60)
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. On RG models, 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. On RG models, 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-248916-S04391504352007022700000).

Scheme 60

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

1. On RG models, install the evaporator temperature sensor and retainer onto the A/C expansion valve, if removed «(Refer to HEATING & AIR CONDITIONING/CONTROLS/EVAPORATOR TEMPERATURE SENSOR - INSTALLATION)»(ref-248916-S06033583972007022700000) .
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. On RG models, 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 ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION)»(ref-248909-S11333827532007022700000) «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION)»(ref-248910-S12179079592007022700000) .
18. Reconnect the negative battery cable.
19. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
20. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

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-248908-S09724997062007022700000).
2. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. (Scheme 61), (Scheme 62) or (Scheme 63). 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 or nipple, while gently pulling it away from the end of the tube or nipple. NOTE: Replacement of the heater inlet hoses 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 or nipple.

Scheme 61

Scheme 62

Scheme 63

1. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed.
2. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube or nipple end.
3. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed.
4. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-248908-S09724997062007022700000) .

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-248908-S09724997062007022700000).
2. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. see scheme 107, see scheme 108 or see scheme 109. 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 or nipple, while gently pulling it away from the end of the tube or nipple. NOTE: Replacement of the heater return hoses 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 or nipple.

1. Using spring tension clamp pliers, compress and slide the clamp away from the end of the heater return hose.
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-248908-S09724997062007022700000) .

Note. The front 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. On models equipped with the rear heating-A/C system, the rear section of the front A/C liquid line also includes a hose and tube extension that connects the front liquid line to the liquid line for the rear A/C system.

1. Recover the refrigerant from the refrigerant system (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Remove the air cleaner housing from the right side of the engine compartment.
3. Remove the bolts that secure both liquid line fittings to the receiver/drier. see scheme 113
4. Disconnect both liquid line fittings from the receiver/drier and remove and discard the O-ring seals.
5. Install plugs in, or tape over the opened liquid line fittings and the receiver/drier ports.
6. Remove the two nuts that secure the receiver/drier mounting bracket to the weld studs on the side of the right front strut tower and remove the receiver/drier.

Note. If the receiver/drier is being replaced, add 25 milliliters (0.8 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 and mounting bracket onto the weld studs on the side of the right front strut tower.
2. Install the two nuts that secure the receiver/drier mounting bracket to the studs. Tighten the nuts to 10 N.m (89 in. lbs.).
3. Remove the tape or plugs from the two liquid line fittings and the receiver/drier ports.
4. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the two liquid line fittings.
5. Connect the liquid line fittings to the receiver/drier.
6. Install the bolt that secures each liquid line fitting to the receiver/drier. Tighten the bolts to 11 N.m (97 in. lbs.).
7. Install the air cleaner housing.
8. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
9. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

Note. The low side A/C service port valve core is serviceable, however, the high side A/C service port valve core is not. If the high side service port valve core is faulty or damaged, the front section of the liquid line will require replacement.

1. Remove the protective cap from the low side service port located on the suction line near the A/C compressor. (Scheme 64)
2. Recover the refrigerant from the refrigerant system (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
3. Using a Schrader-type valve core tool, remove the valve core from the service port.
4. Install a plug in or tape over the opened service port(s).

Scheme 64

1. Lubricate the low side A/C service port valve core with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the compressor in the vehicle.
2. Remove the tape or plug from the A/C service port located on the suction line near the A/C compressor.
3. Using a standard Schrader-type valve core tool, install and tighten the replacement valve core into the low side A/C 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-248916-S20782921882007022700000) ).
5. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).
6. Reinstall the protective cap onto the A/C service port.

Note. The front suction line includes the low side service port near the A/C compressor. On models equipped with the rear A/C system, the front suction line also includes a suction line hose and tube extension that connects the front suction line to the suction line for the rear A/C system.

Scheme 65

1. Recover the refrigerant from the refrigerant system (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000).
2. Disconnect and isolate the negative battery cable.
3. Remove the air cleaner top cover and snorkel from the air cleaner housing located on the right side of the engine compartment.
4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment.
5. Remove the nut that secures the suction line fitting to the top of the A/C compressor.
6. Disconnect the suction line fitting from the compressor suction port and remove and discard the O-ring seal.
7. Install plugs in, or tape over the opened suction line fitting and the compressor suction port.
8. Remove the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment. (Scheme 65) 1 - A/C EXPANSION VALVE 2 - SUCTION LINE EXTENSION (REAR A/C ONLY) 3 - NUT 4 - RETAINING CLIP 5 - SUCTION LINE
9. Remove the nut that secures the suction line and liquid line fittings to the A/C expansion valve.
10. Disconnect the suction line and liquid line fittings from the 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. Remove the suction line from the retaining bracket located at the top of the dash panel.
13. If the vehicle is equipped with the rear heating-A/C system, go to step 14. If the vehicle does not have the rear heating-A/C system, go to step 19.
14. Raise and support the vehicle.
15. Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. see scheme 116 1 - SUCTION LINE EXTENSION TUBE 2 - LIQUID LINE EXTENSION TUBE 3 - RETAINING STRAP 4 - REAR HEATER EXTENSION TUBES 5 - UNDERBODY REFRIGERANT LINES
16. Disconnect the suction line extension fitting from the underbody suction line fitting for the rear A/C system and remove and discard the o-ring seal.
17. Install plugs in, or tape over the opened suction line fittings.
18. Lower the vehicle.
19. Remove the suction line from the engine compartment.

1. Position the suction line into the engine compartment.
2. Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports.
3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction line and liquid line fittings.
4. Reconnect the liquid line and suction line fittings to the expansion valve.
5. Install the nut that secures the suction line and liquid line fittings to the expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
6. Install the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment.
7. Remove the tape or plugs from the compressor suction port and the suction line fitting.
8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting.
9. Install a new dual plan seal and reconnect the suction line fitting to the compressor suction port.
10. Install the nut that secures the suction line fitting to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.).
11. Reconnect the drain tube to the wiper module drain on the right side of the engine compartment.
12. Install the air cleaner top cover and snorkel onto the air cleaner housing located on the right side of the engine compartment.
13. On RHD models, install the suction line into the retaining bracket located at the top of the dash panel.
14. If the vehicle is equipped with the rear heating-A/C system, go to step 15 . If the vehicle does not have the rear heating-A/C system, go to step 21 .
15. Raise and support the vehicle.
16. Remove the tape or plugs from the suction line extension fitting and the underbody suction line fitting.
17. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody suction line fitting.
18. Reconnect the suction line extension fitting to the underbody suction line fitting. Tighten the fittings to 23 N.m (17 ft. lbs.).
19. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system.
20. Lower the vehicle.
21. Reconnect the negative battery cable.
22. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
23. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

1. Remove the rear HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/HVAC HOUSING - REMOVAL)»(ref-248916-S05946612392007022700000).
2. Carefully remove the foam insulating from around the rear A/C expansion valve. (Scheme 66)
3. Remove the rear evaporator line extension from the rear A/C expansion valve «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/A/C EVAPORATOR - EVAPORATOR LINE EXTENSION - REMOVAL)»(ref-248916-S00244088092007022700000).
4. Remove the two screws that secure the rear A/C expansion valve to the rear evaporator tube sealing plate.
5. Remove the rear A/C expansion valve from the rear evaporator tubes and remove and discard the seals.
6. Install plugs in, or tape over the opened evaporator tube fittings, evaporator ports and all expansion valve ports.

Scheme 66

1. Remove the tape or plugs from the rear A/C evaporator tube fittings, rear A/C evaporator ports and all rear expansion valve ports.
2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the rear evaporator tube fittings.
3. Position the rear A/C expansion valve onto the rear evaporator tubes.
4. Install the two screws that secure the rear A/C expansion valve to the rear evaporator tube sealing plate. Tighten the screws to 11 N.m (97 in. lbs.).
5. Install the rear evaporator line extension onto the rear A/C expansion valve «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/A/C EVAPORATOR - EVAPORATOR LINE EXTENSION - INSTALLATION)»(ref-248916-S10343353542007022700000) .
6. Install the foam insulating over the rear A/C expansion valve.
7. Install the rear HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/HVAC HOUSING - INSTALLATION)»(ref-248916-S39888388142007022700000) .

1. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN)»(ref-248908-S09724997062007022700000).
2. Remove the trim panels from the right inner quarter panel and the right D-pillar «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL)»(ref-248887-S07029878172007022700000).
3. Remove the rear heater distribution duct «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/DISTRIBUTION DUCT - REMOVAL)»(ref-248916-S28778870452007022700000).
4. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar.
5. Remove the screw that secures the front of the rear HVAC housing to the right inner quarter panel. NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills.
6. Disconnect the heater hoses from the rear heater core «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER HOSE - REMOVAL)»(ref-248916-S20761806192007022700000).
7. Install plugs in, or tape over the opened heater core fittings and both heater hoses. (Scheme 67)
8. Release the four retaining tabs that secure the rear heater core to the rear HVAC housing and remove the heater core.

Scheme 67

Note. If the rear heater core or the rear HVAC housing have been removed from the vehicle for service, the rear heater core should be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings (Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER CORE - STANDARD PROCEDURE - REAR HEATER CORE FILLING) .

1. Carefully position the rear heater core into the rear HVAC housing.
2. Using hand pressure, press firmly and evenly on the molded plastic tank of the rear heater core until the four retaining tabs that secure the rear heater core in the rear HVAC housing fully engage.
3. Remove the plugs or tape from the rear heater core fittings and both rear heater hoses.
4. Pre-fill the rear heater core «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER CORE - STANDARD PROCEDURE - REAR HEATER CORE FILLING)»(ref-248916-S14814004262007022700000) .
5. Connect the rear heater hoses to the rear heater core «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER HOSE - INSTALLATION)»(ref-248916-S28977550362007022700000) .
6. Install the screw that secures the front of the rear HVAC housing to the right inner quarter panel. Tighten the screw to 11 N.m (97 in. lbs.).
7. Install the screw that secures the back of the rear HVAC housing to the right D-pillar. Tighten the screw to 11 N.m (97 in. lbs.).
8. Install the rear distribution duct «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/DISTRIBUTION DUCT - INSTALLATION)»(ref-248916-S29731571182007022700000) .
9. Install the trim panels onto the right inner quarter panel and the right D-pillar «(Refer to BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION)»(ref-248887-S20438406012007022700000) .
10. If the heater core is being replaced, flush the cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING)»(ref-248908-S09724997062007022700000) .
11. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-248908-S09724997062007022700000) .

1. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN)»(ref-248908-S09724997062007022700000).
2. Raise and support the vehicle.
3. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak.
4. Disconnect the front underbody heater inlet and return hose by carefully twisting the hoses back and forth on the underbody tubes, while gently pulling them away from the end of the tubes. (Scheme 68)
5. If necessary, carefully cut the hose ends and peel the hoses off of the tubes.

Note. Replacement of the heater hoses will be required if the hose ends are cut for removal.

Scheme 68

1. Install the front underbody heater inlet and return hoses by carefully twisting the hoses back and forth on the underbody tubes, while gently pushing them onto the end of the tubes. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak.
2. Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose over the tubes. Release the clamp when it is over the tube.
3. Lower the vehicle.
4. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-248908-S09724997062007022700000) .

Note. On models equipped with the rear A/C system, the rear section of the front A/C liquid line also includes a hose and tube extension that connects the front liquid line to the underbody liquid line.

1. Recover the refrigerant from the refrigerant system (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000).
2. Disconnect and isolate the negative battery cable.
3. Remove the air cleaner housing from the right side of the engine compartment.
4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment.
5. Remove the A/C pressure transducer «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C PRESSURE TRANSDUCER - REMOVAL)»(ref-248916-S09772137262007022700000).
6. If equipped, remove the nut that secures the A/C ground strap to the weld stud on the top of the right front strut tower. see scheme 126
7. If equipped, remove the A/C ground strap eyelet terminal connector from the weld stud.
8. Remove the bolt that secures the rear section of the front liquid line to the top of the receiver/drier.
9. Disconnect the rear section of the front liquid line from the top of the receiver/drier and remove and discard the O-ring seal.
10. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier port.
11. Remove the nut that secures the suction and liquid line to the A/C expansion valve.
12. Disconnect the suction line and liquid lines from the A/C expansion valve and remove and discard the seals.
13. Install plugs in, or tape over the opened suction and liquid line fittings and expansion valve ports. 1 - A/C GROUND STRAP (IF EQUIPPED) 2 - NUT (IF EQUIPPED) 3 - WELD STUD (IF EQUIPPED) 4 - A/C PRESSURE TRANSDUCER 5 - WELD STUD (2) 6 - A/C EXPANSION VALVE 7 - A/C LIQUID LINE (REAR SECTION) 8 - LIQUID LINE EXTENSION (REAR A/C ONLY) 9 - NUT (2) 10 - RECEIVER/DRIER 11 - ROUTING CLIP 12 - A/C LIQUID LINE (FRONT SECTION)
14. Raise and support the vehicle.
15. Remove the tie strap and disconnect the front liquid line from the underbody liquid line and remove and discard the O-ring seal. see scheme 127
16. Install plugs in, or tape over the opened liquid line fittings.
17. Lower the vehicle.
18. Remove the liquid line from the engine compartment.

1. Position the rear section of the front liquid 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. Remove the tape or plugs from the liquid line fitting for the receiver/drier and the receiver/drier port.
7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
8. Reconnect the liquid line to the receiver/drier.
9. Install the bolt that secures the liquid line to the receiver/drier. Tighten the bolt to 11 N.m (97 in. lbs.).
10. If equipped, reinstall the A/C ground strap eyelet terminal connector onto the weld stud on the top of the right front strut tower (if equipped).
11. If equipped, install the nut that secures the A/C ground strap to the weld stud. Tighten the nut to 12 N.m (106 in. lbs.).
12. Install the A/C pressure transducer «(Refer to HEATING & AIR CONDITIONING/CONTROLS/A/C PRESSURE TRANSDUCER - INSTALLATION)»(ref-248916-S09330225442007022700000) .
13. Connect the drain tube to the wiper module drain on the right side of the engine compartment.
14. Install the air cleaner housing into the right side of the engine compartment.
15. Raise and support the vehicle.
16. Remove the tape or plugs from the liquid line rear section extension fitting and the underbody liquid line.
17. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody liquid line.
18. Connect the liquid line rear section extension fitting to the underbody liquid line. Tighten the fittings to 23 N.m (17 ft. lbs.).
19. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system.
20. Lower the vehicle.
21. Reconnect the negative battery cable.
22. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
23. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

Note. On models equipped with the rear A/C system, the rear section of the front A/C suction line also includes a hose and tube extension that connects the front suction line to the underbody suction line.

1. Recover the refrigerant from the refrigerant system (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Disconnect and isolate the negative battery cable.
3. Remove the air cleaner top cover and snorkel from the air cleaner housing located on the right side of the engine compartment.
4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment.
5. Remove the nut that secures the suction line to the A/C compressor.
6. Disconnect the suction line from the A/C compressor and remove and discard the seal.
7. Install plugs in, or tape over the opened suction line fitting and the compressor port.
8. Disengage the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment. see scheme 128 1 - A/C EXPANSION VALVE 2 - SUCTION LINE EXTENSION (REAR A/C ONLY) 3 - NUT 4 - RETAINING CLIP 5 - SUCTION LINE
9. Remove the nut that secures the suction and liquid lines to the front A/C expansion valve.
10. Disconnect the suction and liquid lines from the front A/C expansion valve and remove and discard the O-ring seals.
11. Install plugs in, or tape over the opened suction and liquid line fittings and expansion valve ports.
12. Raise and support the vehicle.
13. Remove the tie strap and disconnect the suction line extension fitting from the underbody suction line and remove and discard the O-ring seal. see scheme 129
14. Install plugs in, or tape over the opened suction line fittings.
15. Lower the vehicle.
16. Remove the suction line from the engine compartment.

1. Position the 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 front A/C expansion valve.
5. Install the nut that secures the suction and liquid lines to the front A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
6. Engage the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment.
7. Remove the tape or plugs from the A/C compressor port and the suction line fitting.
8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting.
9. Connect the suction line to the A/C compressor.
10. Install the nut that secures the suction line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.).
11. Connect the drain tube to the wiper module drain on the right side of the engine compartment.
12. Install the air cleaner top cover and snorkel onto the air cleaner housing located on the right side of the engine compartment.
13. Reconnect the negative battery cable.
14. Raise and support the vehicle.
15. Remove the tape or plugs from the suction line extension fitting and the underbody suction line.
16. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody suction line.
17. Connect the suction line extension fitting to the underbody suction line. Tighten the fitting to 23 N.m (17 ft. lbs.).
18. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system.
19. Lower the vehicle.
20. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
21. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

Note. The air intake tube for the supplemental cabin heater is part of an assembly that includes the heater cooling intake and return pipes. If the cabin heater air intake tube requires removal or replacement the entire cabin heater assembly will require removal or replacement.

Scheme 69

1. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-248908-S09724997062007022700000).
2. Remove clamps from the cabin heater tubes at the lower heater port and the lower EGR connector which are located under the hood.
3. Remove the retaining clamp at the cabin heater air intake muffler connection (Refer to «CABIN HEATER»(ref-248916-S10268755642007030600000) ).
4. Remove the clamp at the flexible tube to steel tube connection. (Scheme 69) 1 - CABIN HEATER AND SPLASH SHIELD 2 - DOSING PUMP 3 - DOSING PUMP FUEL LINE 4 - FLEXIBLE AIR INTAKE LINE 5 - CLAMP 6 - STEEL INTAKE PIPE
5. Remove the two retaining screws and remove pipe assembly. (Scheme 70)

Scheme 70

1. Install the air intake pipe assembly and install the two retaining screws. Tighten the screws to 7 N.m (62 in. lbs.).
2. Attach the steel tube to the flexible tube and position and then tighten the retaining clamp securely.
3. Install the flexible tube to the cabin heater air intake muffler and install and tighten the retaining clamp securely.
4. Install the cabin heater tubes to the lower heater connection and the lower EGR cooler connection and tighten the retaining clamps.
5. Lower the vehicle.
6. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM FILL)»(ref-248908-S09724997062007022700000) .
7. Verify function of the heater unit.

Scheme 71

1. Raise and support the vehicle. Take note of the location of the flexible section of the cabin heater exhaust tube.
2. Remove the exhaust clamp at the flexible pipe and steel pipe connection. (Scheme 71) 1 - MOUNTING SCREWS (3) 2 - STEEL HEATER EXHAUST PIPE 3 - EXHAUST CLAMP (2) 4 - FLEXIBLE HEATER EXHAUST PIPE 5 - CABIN HEATER AND SHIELD 6 - EXHAUST PIPE MOUNTING CLIPS (3) (IF EQUIPPED)
3. Remove the clamp at the flexible pipe connection and the cabin heater housing (if required).
4. Remove the three screws holding the exhaust pipe to the body.
5. Remove the steel exhaust pipe from the vehicle.
6. Remove the flexible exhaust pipe from the vehicle (if required).

1. Install the flexible exhaust pipe to the cabin heater. Tighten the mounting clamp securely.
2. Position the steel exhaust pipe to the flexible exhaust. Tighten the mounting clamp securely.
3. Loosely install the three exhaust pipe screws and adjust pipe placement as required. Tighten the screws securely.
4. Install the clamp that secures the steel exhaust pipe to the flexible exhaust pipe. Tighten the clamp securely.
5. Check exhaust end placement of the exhaust pipe and make any final adjustments.
6. Lower the vehicle.

Note. The dosing pump is serviceable without removing the supplemental cabin heater from the vehicle.

1. Disconnect and isolate the negative battery cable. CAUTION: Make sure that the hoist is properly positioned under the vehicle to prevent damage to the flexible section of the cabin heater exhaust tube.
2. Raise and support the vehicle.
3. Disconnect the wiring harness connector to the dosing pump by depressing the integral spring and pulling the connector away from the pump. NOTE: Utilize an approved fuel storage container to catch any residual fuel that may drain from the heater fuel hose or the dosing pump.
4. Remove the clamp that secures the heater fuel hose to the dosing pump. (Scheme 72)
5. Disconnect the heater fuel hose from the dosing pump. NOTE: Position and retain the heater fuel line to prevent fuel leakage from the cabin heater unit while servicing the dosing pump.
6. Disconnect the fuel line between the dosing pump and the cabin heater unit. NOTE: Have an approved fuel storage container ready to catch any residual fuel that may drain from the fuel line or the cabin heater unit.
7. Remove the dosing pump from the rubber isolator and the vehicle.

Scheme 72

1. Position the dosing pump to the vehicle and onto the rubber isolator.
2. Connect the fuel line between the dosing pump and the cabin heater unit. NOTE: The connectors should point towards the cabin heater fuel line.
3. Connect the heater fuel hose to the dosing pump.
4. Install the clamp that secures the heater fuel hose to the dosing pump. Tighten the clamp securely.
5. Connect the wire harness connector to the dosing pump by depressing the integral spring and pushing the connector toward the pump. Verify connector installation.
6. Lower the vehicle
7. Reconnect the negative battery cable.
8. Verify function of the supplemental cabin heater.

1. Raise and support the vehicle. NOTE: Utilize an approved fuel storage container to catch any residual fuel that may drain from the heater fuel hose or the dosing pump.
2. Remove the two clamps that secure the heater fuel hose to the dosing pump and the heater fuel line. see scheme 143
3. Disconnect the heater fuel hose from the dosing pump and the heater fuel line.
4. Remove the clamp that secures the heater fuel line to the fuel tank.
5. Disconnect the heater fuel line from the fuel tank.
6. Disconnect the fuel line from the body retaining clips and remove the fuel line from vehicle.

1. Position the cabin heater fuel line to the vehicle and connect the body retaining clips.
2. Connect the heater fuel line to the fuel tank.
3. Install the clamp that secure the heater fuel line to the fuel tank. Tighten the clamp securely.
4. Connect the heater fuel hose to the dosing pump and the heater fuel line.
5. Install the clamps that secure the heater fuel hose to the dosing pump and the heater fuel line. Tighten the clamps securely.
6. Lower the vehicle. NOTE: Verify that there is more than 1/8 of a tank of fuel in the vehicle's fuel tank before performing this procedure. Add fuel, if necessary. NOTE: Failure to prime the dosing pump after draining the supplemental cabin fuel line will prevent cabin heater activation during the first attempt to start the cabin heater. This will also set a diagnostic trouble code (DTC) in the cabin heater control's memory. Do not perform the Dosing Pump Priming procedure if an attempt was made to start the cabin heater without priming the dosing pump first. This will put excess fuel in the cabin heater and cause smoke to emit from the cabin heater exhaust pipe when cabin heater activation occurs.
7. Connect the DRBIII® scan tool to the diagnostic link connector.
8. Turn the ignition to the ON position. NOTE: Do not activate the dosing pump prime more than one time. This will put excess fuel in the supplemental cabin heater and cause smoke to emit from the cabin heater exhaust pipe when cabin heater activation occurs. NOTE: A clicking noise heard coming from the dosing pump indicates that the pump is operational.
9. With the DRBIII® scan tool in Cabin Heater, select System Tests and Dosing Pump Prime. Allow the dosing pump to run for the full 45 second cycle time. When the 45 second cycle is complete, press Page Back on the DRBIII® scan tool key pad to exit the Dosing Pump Prime. The Dosing Pump Priming procedure is now complete.

1. Raise and support the vehicle. Take note of the location of the flexible section of the cabin heater exhaust tube.
2. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-248908-S09724997062007022700000) . NOTE: Complete removal of the supplemental cabin heater from vehicle is not required, lowering the cabin heater allows easier access to coolant line clamps.
3. Lower the supplemental cabin heater from the vehicle «(Refer to HEATING & AIR CONDITIONING/CABIN HEATER/HEATER UNIT - REMOVAL)»(ref-248916-S26360850102007022700000) .
4. Remove the clamps from both flexible coolant line ends. NOTE: It is recommended that both flexible cabin heater coolant lines be replaced if either cabin heater coolant line is damaged.
5. Remove both coolant lines from vehicle.

1. Install both flexible coolant lines to the supplemental cabin heater and install the clamps.
2. Install the flexible coolant lines to the coolant pipes and install the clamps.
3. Install the supplemental cabin heater into the vehicle «(Refer to HEATING & AIR CONDITIONING/CABIN HEATER/HEATER UNIT - INSTALLATION)»(ref-248916-S14290335232007022700000) .
4. Lower the vehicle.
5. Fill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-248908-S09724997062007022700000) .
6. Verify operation of the supplemental cabin heater.

Note. Steel heater lines from engine compartment to the supplemental cabin heater are part of an assembly that includes the air intake pipe. If the cabin heater lines or air intake pipe require removal or replacement the entire cabin heater assembly will require removal or replacement.

Scheme 73

1. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-248908-S09724997062007022700000).
2. Remove clamps from both the EGR cooler and the lower heater port. Separate hoses from the mating plumbing port. (Scheme 73) 1 - HEATER CORE INTAKE PIPE 2 - HEATER CORE RETURN PIPE 3 - A/C LINES 4 - A/C EXPANSION VALVE 5 - A/C EXPANSION VALVE GROUND WIRE 6 - CABIN HEATER RETURN PIPE 7 - CABIN HEATER INTAKE PIPE 8 - CABIN HEATER PIPES RETAINING NUT
3. Remove retaining nut from heater line under hood bracket.
4. Raise and support the vehicle. Take note of the location of the flexible section of the cabin heater exhaust tube.
5. Remove the clamps from cabin heater lines to the rubber connection nearest the tubes. Separate the hoses from the tube assembly leaving the rubber hose attached to the cabin heater.
6. Remove the cabin heater intake pipe from the heater unit «(Refer to HEATING & AIR CONDITIONING/CABIN HEATER/INLET HOSE - REMOVAL)»(ref-248916-S36950456542007022700000). see scheme 145
7. Remove heater pipe assembly retaining screws and remove assembly from vehicle.

1. Position the heater pipe assembly and install the retaining screws.
2. Install the heater unit intake pipe to the heater unit «(Refer to HEATING & AIR CONDITIONING/CABIN HEATER/INLET HOSE - INSTALLATION)»(ref-248916-S38779016442007022700000) .
3. Connect heater hoses to the heater unit and tighten the clamps.
4. Install heater unit intake pipe to heater unit «(Refer to HEATING & AIR CONDITIONING/CABIN HEATER/INLET HOSE - INSTALLATION)»(ref-248916-S38779016442007022700000) .
5. Lower the vehicle.
6. Install and tighten the retaining nut to the heater line under the hood bracket.
7. Connect the heater lines to the heater hoses at the heater core and EGR port. Position spring clamps onto the hoses.
8. Fill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-248908-S09724997062007022700000) .

1. Elevate vehicle on a lift taking note of the exhaust tube flexible section.
2. Unplug connector from vehicle wiring harness to cabin heater harness.
3. Unplug connector from cabin heater harness to dosing pump connector.
4. Unplug two connectors from cabin heater harness to cabin heater controller connectors.
5. Remove two wiring harness connectors from underbody.
6. Remove two wiring harness connectors from cabin heater shield.
7. Carefully route the cabin heater harness to the left side between the cabin heater unit and the cabin heater shield.

1. Carefully route the cabin heater harness from the left side of the cabin heater between the cabin heater unit and the cabin heater shield.
2. Install the two wiring harness retaining connectors to the cabin heater shield.
3. Route the wiring harness along the underside of the vehicle and install the two wiring harness retaining connectors.
4. Plug the two connectors from the cabin heater harness to the cabin heater controller.
5. Plug the connector to the cabin heater harness to the dosing pump connector.
6. Plug the connector from the vehicle wiring harness to the cabin heater harness.
7. Lower the vehicle.
8. Verify function of the cabin heater.