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Heating, Ventilation, and Air Conditioning: Removal & Installation GMC Sierra 2500 HD

Automatic HVAC System 16 illustrations ~5011 words

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  2. Install a ratchet into the belt tensioner adapter opening.
  3. Rotate the belt tensioner counterclockwise in order to relieve the tension on the belt.
  4. Remove the belt from the A/C compressor.
  5. Slowly release the tension on the belt tensioner.
  6. Remove the discharge hose bolt (2) from the A/C compressor (3).
  7. Remove the discharge hose (1) from the A/C compressor (3).
  8. Remove the suction hose bolt (2) from the A/C compressor (3).
  9. Remove the suction hose (1) from the A/C compressor (3).
  10. Discard the sealing washers. Cap all of the openings.
  11. Disconnect the electrical connections.
  12. Remove the A/C compressor mounting bolts.
  13. If replacing the A/C compressor. Refer to «Compressor Oil Balancing»(ref-277995-S05923328332008012100000) .

Installation Procedure

  1. Remove the caps or tape from the hose and line ends.
  2. Install the A/C compressor.
  3. Install the A/C compressor mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  4. Connect the electrical connection.
  5. Install the A/C discharge hose (1) to the compressor (3) using new sealing washers.
  6. Install the A/C discharge hose bolt (2) to the A/C compressor (3). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  7. Install the A/C suction hose (1) to the compressor (3) using new sealing washers.
  8. Install the A/C suction hose bolt (2) to the A/C compressor (3). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  9. Install the drive belt. Refer to «Drive Belt Replacement»(ref-278093-S32518826922008012100000) .
  10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  11. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-277995-S42237343062008012100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  2. Install a ratchet into the belt tensioner adapter opening.
  3. Rotate the belt tensioner counterclockwise in order to relieve the tension on the belt.
  4. Remove the belt from the A/C compressor.
  5. Slowly release the tension on the belt tensioner.
  6. Remove the discharge and suction hose bolt from the A/C compressor.
  7. Remove the discharge and suction hose from the A/C compressor.
  8. Discard the sealing washers. Cap all of the openings.
  9. Disconnect the electrical connections.
  10. Remove the A/C compressor mounting bolts.
  11. If replacing the A/C compressor. Refer to «Compressor Oil Balancing»(ref-277995-S05923328332008012100000) .
  1. Remove the caps or tape from the hose and line ends.
  2. Install the A/C compressor.
  3. Install the A/C compressor mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  4. Connect the electrical connection.
  5. Install the A/C discharge and suction hose to the compressor using new sealing washers.
  6. Install the A/C discharge and suction hose bolt to the A/C compressor. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  7. Install the drive belt. Refer to «Drive Belt Replacement»(ref-278083-S23085427542008012100000) .
  8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  9. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-277995-S42237343062008012100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  2. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
  3. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-278009-S05538658182008012100000) .
  4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
  5. Remove the A/C belt from the A/C compressor.
  6. Slowly release the tension on the A/C belt tensioner.
  7. Remove the discharge hose bolt from the A/C compressor.
  8. Remove the discharge hose from the A/C compressor.
  9. Remove the suction hose bolt from the A/C compressor.
  10. Remove the suction hose from the A/C compressor.
  11. Discard the sealing washers. Cap all of the openings.
  12. Disconnect the electrical connections.
  13. Remove the A/C compressor mounting bolts. The lower right bolt (3) will stay with the compressor due to a lack of clearance.
  14. Remove the A/C compressor (2) from the bracket (1).
  15. If replacing the A/C compressor. Refer to «Compressor Oil Balancing»(ref-277995-S05923328332008012100000) .
  1. Install the A/C compressor (2) to the bracket (1) through the fender well. Insert the mounting bolt (3) into the lower right mounting boss before installing the A/C compressor.
  2. Install the A/C compressor to the bracket. Insert the mounting bolt into the lower right mount before installing the A/C compressor.
  3. Install the A/C compressor mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  4. Connect the electrical connector to the A/C compressor.
  5. Install the A/C discharge hose to the compressor using new sealing washers. Refer to «Sealing Washer Replacement»(ref-277995-S10601441322008012100000) .
  6. Install the A/C discharge hose bolt to the A/C compressor. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  7. Install the A/C suction hose to the compressor using new sealing washers. Refer to «Sealing Washer Replacement»(ref-277995-S10601441322008012100000) .
  8. Install the A/C suction hose bolt to the A/C compressor. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  9. Install the A/C drive belt. Refer to «Air Conditioning Compressor Belt Replacement»(ref-278040-S28265234662008012100000) .
  10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  11. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-278009-S05538658182008012100000) .
  12. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-277995-S42237343062008012100000) .
  1. Install a ratchet into the air conditioning belt tensioner adapter opening.
  2. Rotate the belt tensioner counterclockwise in order to relieve the tension on the belt.
  3. Remove the belt from the air conditioning (A/C) compressor.
  4. Slowly release the tension on the A/C belt tensioner.
  5. Remove the clutch plate retaining bolt (1).
  6. Remove the clutch plate assembly (2).
  7. Remove the clutch hub/bearing snap ring (3).
  8. Remove the clutch hub/bearing assembly (4).
  9. Remove the snap ring (5) from the clutch coil (6).
  10. Remove the clutch coil (6) from the A/C compressor (7).
  1. Install the clutch coil (6) to the A/C compressor (7).
  2. Install the snap ring (5) to the clutch coil (6).
  3. Install the clutch hub/bearing assembly (4).
  4. Install the clutch hub/bearing snap ring (3).
  5. Place a small amount of oil on the thinnest air gap shim and place it inside the clutch plate.
  6. Install the clutch plate assembly (2).
  7. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.35-0.65 mm (0.014-0.026 in) air gap.
  8. Install the clutch plate retaining bolt (1). Tighten: Tighten the bolt to 18 N.m (13 lb ft).
  9. Install a ratchet into the belt tensioner adapter opening.
  10. Rotate the belt tensioner counterclockwise in order to relieve the tension on the belt.
  11. Install the belt to the A/C compressor.
  12. Slowly release the tension on the belt tensioner.
  13. Remove the ratchet from the belt tensioner.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-278014-S01448585812008012100000) .
  2. Remove the engine protection shield.
  3. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
  4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
  5. Remove the A/C belt from the A/C compressor.
  6. Slowly release the tension on the A/C belt tensioner.
  7. Remove the clutch plate retaining bolt (1).
  8. Remove the clutch plate assembly (2).
  9. Remove the clutch hub/bearing snap ring (3).
  10. Remove the clutch hub/bearing assembly (4).
  11. Remove the snap ring (5) from the clutch coil (6).
  12. Remove the clutch coil (6) from the A/C compressor (7).
  1. Install the clutch coil (6) to the A/C compressor (7).
  2. Install the snap ring (5) to the clutch coil (6).
  3. Install the clutch hub/bearing assembly (4).
  4. Install the clutch hub/bearing snap ring (3).
  5. Place a small amount of oil on the thinnest air gap shim and place it inside the clutch plate.
  6. Install the clutch plate assembly (2).
  7. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.35-0.65 mm (0.014-0.026 in) air gap.
  8. Install the clutch plate retaining bolt (1). Tighten: Tighten the bolt to 18 N.m (13 lb ft).
  9. Install a ratchet into the A/C belt tensioner adapter opening.
  10. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
  11. Install the A/C belt to the A/C compressor.
  12. Slowly release the tension on the A/C belt tensioner.
  13. Remove the ratchet from the A/C belt tensioner.
  14. Install the engine protection shield.
  15. Lower the vehicle.
  1. Remove the A/C compressor. Refer to «Compressor Replacement (LLY/LMM)»(ref-277995-S12308118622008012100000) or «Compressor Replacement (LU3)»(ref-277995-S30151616812008012100000) or «Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG)»(ref-277995-S30727191062008012100000) .
  2. Remove the A/C belt tensioner bolts.
  3. Remove the A/C belt tensioner.
  4. Remove the A/C compressor bracket mounting bolts.
  5. Remove the A/C compressor bracket.
  1. Install the A/C compressor bracket.
  2. Install the A/C compressor bracket mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  3. Install the A/C belt tensioner.
  4. Install the A/C belt tensioner bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  5. Install the A/C compressor. Refer to «Compressor Replacement (LLY/LMM)»(ref-277995-S12308118622008012100000) or «Compressor Replacement (LU3)»(ref-277995-S30151616812008012100000) or «Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG)»(ref-277995-S30727191062008012100000) .
  1. Remove the seal washer from the A/C refrigerant component.
  2. Inspect the seal washer for signs of damage to help determine the root cause of the failure.
  3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
  4. Discard the sealing washer.
  1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
  2. Remove the cap or tape from the A/C refrigerant components.
  3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
  4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting.
  5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.
  1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). For banjo style fittings remove the bolt retaining the banjo type fitting.
  2. Remove the O-ring seal from the A/C refrigerant component.
  3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.
  4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
  5. Cap or tape the A/C refrigerant components.
  6. Discard the O-ring seal.
  1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
  2. Remove the cap or tape from the A/C refrigerant components.
  3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.
  4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
  5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
  6. The O-ring seal must be fully seated.
  7. Assemble the A/C components. Refer to the appropriate repair procedure. For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  2. Remove the discharge hose mounting bolt (2) from the A/C compressor.
  3. Remove the discharge hose (1) from the A/C compressor.
  4. Remove the upper radiator baffle. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-277993-S24927827062008012100000) .
  5. Remove the discharge hose nut from the condenser.
  6. Remove the discharge hose from the condenser.
  7. Disconnect the electrical connector from the A/C recirculation switch.
  8. Remove the discharge hose from the vehicle.
  9. Discard all of the used sealing washers. Cap the system openings.
  1. Install the discharge hose (1) to the vehicle.
  2. Connect the electrical connector to the A/C recirculation switch.
  3. Install the discharge hose to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-277995-S10601441322008012100000) .
  4. Install the discharge hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install the upper air baffle. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-277993-S24927827062008012100000) .
  6. Install the discharge hose (1) to the A/C compressor using new sealing washers. Refer to «Sealing Washer Replacement»(ref-277995-S10601441322008012100000) .
  7. Install the discharge hose mounting bolt. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  9. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-277995-S42237343062008012100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  2. Remove the discharge hose mounting bolt (2) from the A/C compressor. Discard the bolt.
  3. Remove the discharge hose (5) from the A/C compressor.
  4. Remove the upper radiator air baffle. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-277993-S24927827062008012100000) .
  5. Remove the discharge hose nut from the condenser. Discard the nut.
  6. Remove the discharge hose from the condenser.
  7. Disconnect the A/C recirculation switch from the discharge hose.
  8. Remove the discharge hose from the vehicle.
  9. Discard all of the used sealing washers. Cap the system openings.
  1. Install the discharge hose to the vehicle.
  2. Connect the A/C recirculation switch to the discharge hose.
  3. Install the discharge hose to the condenser using new sealing washers.
  4. Install the NEW discharge hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install the upper radiator air baffle. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-277993-S24927827062008012100000) .
  6. Install the discharge hose (5) to the compressor using new sealing washers.
  7. Install the NEW discharge hose mounting bolt (2) to the A/C compressor. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  9. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-277995-S42237343062008012100000) .

Scheme 3

Scheme 3: Suction Hose Replacement (LY2, LMF, L76 and L92)
Scheme 3: Suction Hose Replacement (LY2, LMF, L76 and L92)
CalloutComponent Name
Preliminary Procedure: Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
1Suction Hose Bolt NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Suction Hose Nut Tighten: 9 N.m (80 lb in)
3Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
4A/C Suction Hose
NOTE
Refer to Fastener Notice .

Suction Hose Replacement (LY2, LMF, L76 and L92)

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  2. Remove the suction hose mounting bolt (3) from the A/C compressor. Discard the bolt.
  3. Remove the suction hose (1) from the compressor.
  4. Remove the suction hose nut from the accumulator. Discard the nut.
  5. Remove the suction hose from the accumulator.
  6. Remove the suction hose from the vehicle.
  7. Discard all of the used sealing washers. Cap the system openings.
  1. Install the suction hose to the vehicle using new sealing washers.
  2. Install the suction hose to the accumulator.
  3. Install the NEW suction hose nut to the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  4. Install the suction hose to the compressor (1).
  5. Install the NEW suction hose mounting bolt (3). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  6. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  7. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-277995-S42237343062008012100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  2. Remove the upper radiator air baffle and deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-277993-S24927827062008012100000) .
  3. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-278009-S34765943782008012100000) .
  4. Remove the surge tank hold down nut and bolt and position aside.
  5. Remove the evaporator tube nut from the evaporator.
  6. Disconnect the evaporator tube from the evaporator.
  7. Remove the evaporator tube nut from the auxiliary A/C tube, if equipped.
  8. Disconnect the evaporator tube from the auxiliary A/C tube, if equipped.
  9. Remove the evaporator tube nut from the condenser.
  10. Disconnect the evaporator tube from the condenser.
  11. Remove the evaporator tube from the vehicle.
  12. Discard all of the used sealing washers. Cap all of the open connections.
  1. Connect the evaporator tube to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-277995-S10601441322008012100000) .
  2. Install the evaporator tube nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  3. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers, if equipped. Refer to «Sealing Washer Replacement»(ref-277995-S10601441322008012100000) .
  4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install the evaporator tube to the evaporator.
  6. Install the evaporator tube nut to the evaporator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  7. Install the surge tank hold down nut and bolt and position aside.
  8. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-278009-S34765943782008012100000) .
  9. Install the upper radiator air baffle and deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-277993-S24927827062008012100000) .
  10. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  11. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-277995-S42237343062008012100000) .

Scheme 4

Scheme 4: Expansion (Orifice) Tube Replacement
Scheme 4: Expansion (Orifice) Tube Replacement
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1Orifice Tube Fitting NOTE: Refer to Fastener Notice . Tip: Loosen orifice tub fitting and separate the pressure line to access the orifice. Tighten: 9 N.m (80 lb in)
2O-ring Seal Tip: Remove and discard O-ring. Refer to O-Ring Replacement .
3Orifice Tube Assembly Tip: Use J 26549-E to remove orifice tube. See Special Tools .
NOTE
Refer to Fastener Notice .

Expansion (Orifice) Tube Replacement

  1. Disconnect the electrical connector from the A/C low pressure switch.
  2. Remove the A/C low pressure switch from the accumulator.
  3. Remove the O-ring and discard.
  1. Install the new O-ring seal to the switch. Refer to «O-Ring Replacement»(ref-277995-S13600758692008012100000) .
  2. Install the A/C low pressure switch to the accumulator. Tighten: Tighten the switch to 6 N.m (53 lb in).
  3. Connect the electrical connector to the A/C low pressure switch.
  4. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-277995-S42237343062008012100000) .
  1. Disconnect the electrical connector from the A/C high pressure recirculation switch.
  2. Remove the A/C high pressure recirculation switch (1) from the condenser tube.
  1. Install the A/C high pressure recirculation switch (1). Tighten: Tighten the switch to 6 N.m (53 lb in).
  2. Connect the electrical connector to the A/C high pressure recirculation switch.
  3. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-277995-S42237343062008012100000) .
  4. Lower the vehicle.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  2. Remove radiator support bolts (1). Access the bolts from the rear of the upper radiator support. Refer to «Radiator Support Replacement»(ref-278005-S14229132292008012100000) .
  3. Remove the compressor discharge hose assembly bolt from the condenser.
  4. Disconnect the compressor discharge hose assembly from the condenser.
  5. Remove the evaporator tube nut from the condenser.
  6. Disconnect the evaporator tube from the condenser.
  7. Remove the insulator retainer bolts and the upper insulator retainers.
  8. Remove the condenser from the vehicle.
  1. Install the condenser to the vehicle.
  2. Install the upper insulator retainers and the insulator retainer bolts. Tighten: Tighten the bolts to 2.4 N.m (21 lb in).
  3. Connect the evaporator tube to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-277995-S10601441322008012100000) .
  4. Install the evaporator tube nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Connect the compressor discharge hose to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-277995-S10601441322008012100000) .
  6. Install the compressor discharge hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  7. Install the lower bolts to the hood latch support bracket. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  8. Install the radiator support. Access the bolts (1) from the rear of the upper radiator support. Refer to «Radiator Support Replacement»(ref-278005-S14229132292008012100000) . Tighten: Tighten the nut to 16 N.m (12 lb ft).
  9. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(ref-277995-S07969845602008012100000) .
  10. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-277995-S42237343062008012100000) .

Scheme 5

Scheme 5: Accumulator Replacement
Scheme 5: Accumulator Replacement
CalloutComponent Name
Preliminary Procedure: Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
1Suction Hose Nut NOTE: Refer to Fastener Notice . Tip: Large A/C compressor hose to A/C evaporator. Tighten: 16 N.m (12 lb in)
2A/C Suction Hose
3Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
4Accumulator Mounting Bracket Nut Tighten: 16 N.m (12 lb in)
5Accumulator Nut Tighten: 16 N.m (12 lb in)
6Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
7Accumulator Tip: Replacement service accumulators are shipped dry (no PAG oil). Add proper amount of oil to system before operating. Refer to Refrigerant System Capacities .
NOTE
Refer to Fastener Notice .

Accumulator Replacement

  1. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-277993-S38409875582008012100000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-277993-S13526624712008012100000) .
  2. Using the J 43181 disconnect the inlet heater hose from the heater core. Install the J 43181 to the heater core pipe. Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core.
  3. Using the J 43181 disconnect the surge tank outlet hose from the heater core. Install the J 43181 to the heater core pipe. Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core.
  4. Remove the upper intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-278040-S04114410222008012100000) .
  5. Remove the battery. Refer to «Battery Replacement»(ref-278006-S19098885142008012100000) .
  6. Remove the accumulator. Refer to «Accumulator Replacement»(ref-277995-S24214577902008012100000) .
  7. Remove the instrument panel carrier. Refer to «Instrument Panel Carrier Support Replacement (without RPO SLT)»(ref-277985-S15523396762008012100000) or «Instrument Panel Carrier Support Replacement (with RPO SLT)»(ref-277985-S22654430052008012100000) .
  8. Remove the nuts (2) from the HVAC module (3).
  9. Remove the bolts (1) from the HVAC module (3).
  10. Remove the HVAC module (3).
  1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary.
  2. Install the HVAC module (3).
  3. Install the nuts (2) to the HVAC module (3). Tighten: Tighten the nuts to 9 N.m (80 lb in).
  4. Install the bolts (1) to the HVAC module (3). Tighten: Tighten the bolts to 4 N.m (35 lb in).
  5. Connect the electrical harness and the ground connections.
  6. Install the HVAC module drain hose.
  7. Install the instrument panel carrier. Refer to «Instrument Panel Carrier Replacement»(ref-277985-S38684641942008012100000) .
  8. Install the upper intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-278040-S04114410222008012100000) .
  9. Install the battery. Refer to «Battery Replacement»(ref-278006-S19098885142008012100000) .
  10. Install the accumulator. Refer to «Accumulator Replacement»(ref-277995-S24214577902008012100000) .
  11. Install the surge tank outlet hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  12. Install the inlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  13. Fill the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-277993-S38409875582008012100000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-277993-S13526624712008012100000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer.
  3. Disconnect all wiring connections from blower motor, blower motor control module and sensors. Also, remove all wiring from retainers before removal.
  4. If equipped remove the screws from the HVAC module assembly.
  5. Remove the evaporator cowl gasket from the evaporator.
  6. Separate the upper HVAC module assembly (2) from the lower HVAC module assembly (1)
  7. Remove the evaporator core (1) from the upper HVAC module assembly (2).
  1. Install the evaporator core (1) to the HVAC module assembly (2).
  2. Install the upper HVAC module assembly (2) from the lower HVAC module assembly (1)
  3. Install the evaporator cowl gasket to the evaporator.
  4. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-277993-S38409875582008012100000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-277993-S13526624712008012100000) .
  2. Remove the air intake tube.
  3. Remove the heater and surge tank hoses from the mounting clip.
  4. Squeeze the plastic retainer release tabs.
  5. Pull the connection apart.
  6. Remove the inlet heater hose from the water pump.
  7. Remove the inlet heater hose.
  1. Install the inlet heater hose.
  2. Install the inlet heater hose to the water pump.
  3. Connect the heater hose to the heater core.
  4. Install the heater and surge tank hoses to the mounting clip.
  5. Install the air intake tube.
  6. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-277993-S38409875582008012100000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-277993-S13526624712008012100000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-277993-S38409875582008012100000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-277993-S13526624712008012100000) .
  2. Remove the air intake tube.
  3. Remove the heater and surge tank hoses from the mounting clip.
  4. Squeeze the plastic retainer release tabs.
  5. Pull the connection apart.
  6. Remove the outlet heater hose from the water pump.
  7. Reposition the outlet heater hose clamp at the surge tank.
  8. Remove the outlet heater hose from the surge tank.
  9. Remove the outlet heater hose.
  1. Install the outlet heater hose.
  2. Install the outlet heater hose to the water pump.
  3. Install the outlet heater hose to the surge tank.
  4. Install the outlet heater hose clamp to the surge tank.
  5. Connect the heater and surge tank hoses to the heater core.
  6. Pull the heater outlet hose to ensure the connection.
  7. Install the heater and surge tank hoses to the mounting clip.
  8. Install the air intake tube.
  9. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-277993-S38409875582008012100000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-277993-S13526624712008012100000) .

Scheme 6

Scheme 6: Air Inlet Assembly Replacement
Scheme 6: Air Inlet Assembly Replacement
CalloutComponent Name
Preliminary Procedure Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement . Disconnect the electrical connector from the recirculation actuator.
1Recirculation Actuator Screw (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2Recirculation Actuator
3Air Inlet Assembly Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
4Air Inlet Assembly Tip: Tilt the rear of the air inlet assembly upward to release front mounting tabs.
NOTE
Refer to Fastener Notice .

Air Inlet Assembly Replacement

Scheme 7

Scheme 7: Blower Motor Control Module Replacement
Scheme 7: Blower Motor Control Module Replacement
CalloutComponent Name
Preliminary Procedure Remove the I/P insulator panel. Refer to Instrument Panel Insulator Replacement (Without RPO SLT) or Instrument Panel Insulator Replacement (with RPO SLT) . Disconnect the blower motor control module electrical connector.
1Blower Motor Control Module Screw (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2Blower Motor Control Module
NOTE
Refer to Fastener Notice .

Blower Motor Control Module Replacement

  1. If equipped, remove the sound insulator panel. Refer to «Instrument Panel Insulator Replacement (Without RPO SLT)»(ref-277985-S28578967672008012100000) or «Instrument Panel Insulator Replacement (with RPO SLT)»(ref-277985-S13117684002008012100000) .
  2. Remove the blower motor insulating cover screws.
  3. Disconnect the electrical connector from the blower motor.
  4. Remove the blower motor insulating cover.
  5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module.
  6. Remove the blower motor.
  1. Install the blower motor.
  2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place.
  3. Install the blower motor insulating cover.
  4. Connect the electrical connector to the blower motor.
  5. Install the blower motor insulating cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  6. If equipped, install the sound insulator panel. Refer to «Instrument Panel Insulator Replacement (Without RPO SLT)»(ref-277985-S28578967672008012100000) or «Instrument Panel Insulator Replacement (with RPO SLT)»(ref-277985-S13117684002008012100000) .

Scheme 8

Scheme 8: Air Distributor Duct Replacement
Scheme 8: Air Distributor Duct Replacement
CalloutComponent Name
Preliminary Procedure: Remove the I/P trim panel - upper. Refer to Instrument Panel Upper Trim Panel Replacement (without RPO SLT) or Instrument Panel Upper Trim Panel Replacement (with RPO SLT) .
1Air Distributor Bolts and Rivets (Qty: 6) NOTE: Refer to Fastener Notice . Tighten: 2.5 N.m (16 lb in)
2Air Distributor Duct
NOTE
Refer to Fastener Notice .

Air Distributor Duct Replacement

Scheme 9

Scheme 9: Side Window Air Outlet Replacement
Scheme 9: Side Window Air Outlet Replacement
CalloutComponent Name
1Air Outlet Assembly - Side Window - Left Tip: Insert a flat-bladed plastic trim tool along the forward edge of the outlet and release the retaining tabs securing the outlet to the instrument panel.
2Air Outlet Assembly - Side Window - Right Tip: Insert a flat-bladed plastic trim tool along the left inboard edge of the outlet and release the retaining tabs securing the outlet to the instrument panel.

Side Window Air Outlet Replacement

Scheme 10

Scheme 10: Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT)
Scheme 10: Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT)
CalloutComponent Name
1Instrument Panel Trim Plate Refer to Instrument Panel Trim Plate Replacement
2Instrument Panel Air Outlet Assembly - Left Tip: Release the retaining tabs securing the outlet to the instrument panel trim plate.

Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT)

Scheme 11

Scheme 11: Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT)
Scheme 11: Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT)
CalloutComponent Name
1Instrument Panel Air Outlet Assembly - Left Tip: Use a flat-bladed plastic trim tool to release the retainer clip on the right side of the air outlet assembly, securing the air outlet assembly to the instrument panel.
2Retainer Clip (Qty: 1)

Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT)

Scheme 12

Scheme 12: Instrument Panel Center Air Outlet Replacement (without RPO SLT)
Scheme 12: Instrument Panel Center Air Outlet Replacement (without RPO SLT)
CalloutComponent Name
1Instrument Panel Accessory Trim Plate Refer to Instrument Panel Accessory Trim Plate Replacement (without RPO SLT) or Instrument Panel Accessory Trim Plate Replacement (with RPO SLT)
2Instrument Panel Center Air Outlet Assembly - Left Tip: Release the retaining tabs securing the outlet to the instrument panel accessory trim plate.
3Instrument Panel Center Air Outlet Assembly - Right Tip: Release the retaining tabs securing the outlet to the instrument panel accessory trim plate.

Instrument Panel Center Air Outlet Replacement (without RPO SLT)

Scheme 13

Scheme 13: Instrument Panel Center Air Outlet Replacement (With RPO SLT)
Scheme 13: Instrument Panel Center Air Outlet Replacement (With RPO SLT)
CalloutComponent Name
1Instrument Panel Center Trim Panel Refer to Instrument Panel Center Trim Panel Replacement (with RPO SLT) .
2Instrument Panel Center Air Deflector - Left Tip: Release the tabs securing the air deflector to the trim panel.
3Instrument Panel Center Air Deflector - Right Tip: Release the tabs securing the air deflector to the trim panel.

Instrument Panel Center Air Outlet Replacement (With RPO SLT)

Scheme 14

Scheme 14: Instrument Panel Outer Air Outlet Replacement - Right Side (without RPO SLT)
Scheme 14: Instrument Panel Outer Air Outlet Replacement - Right Side (without RPO SLT)
CalloutComponent Name
1Instrument Panel Upper Trim Panel Refer to Instrument Panel Upper Trim Panel Replacement (without RPO SLT) or Instrument Panel Upper Trim Panel Replacement (with RPO SLT) .
2Instrument Panel Air Outlet Screw (Qty: 3) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
3Instrument Panel Air Outlet Assembly - Right
NOTE
Refer to Fastener Notice .

Instrument Panel Outer Air Outlet Replacement - Right Side (without RPO SLT)

Scheme 15

Scheme 15: Instrument Panel Outer Air Outlet Replacement - Right Side (with RPO SLT)
Scheme 15: Instrument Panel Outer Air Outlet Replacement - Right Side (with RPO SLT)
CalloutComponent Name
Preliminary Procedure: Remove the instrument panel center trim panel. Refer to Instrument Panel Center Trim Panel Replacement (with RPO SLT) .
1Instrument Panel Air Outlet Assembly Screw (Qty: 1) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
2Instrument Panel Air Outlet - Right Tip: Use a flat-bladed plastic trim tool to release the retainer clip on the left side of the air outlet assembly, securing the air outlet assembly to the instrument panel.
3Retainer Clip (Qty: 1)
NOTE
Refer to Fastener Notice .

Instrument Panel Outer Air Outlet Replacement - Right Side (with RPO SLT)

  1. Remove the push pin (5) from the left floor air outlet duct (4).
  2. Remove the left floor duct (1) from the HVAC module (2).
  1. Install the left floor air outlet duct (1) to the HVAC module (2).
  2. Install the push pin (2) to the left floor air outlet duct.

Scheme 16

Scheme 16: Floor Air Outlet Duct Replacement - Right Side
Scheme 16: Floor Air Outlet Duct Replacement - Right Side
CalloutComponent Name
Preliminary Procedure Remove the I/P insulator. Refer to Instrument Panel Insulator Replacement (Without RPO SLT) or Instrument Panel Insulator Replacement (with RPO SLT) . Remove the front floor console side trim panel - right. Refer to Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) .
1Air Duct Bolt NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2Air Outlet Duct - Floor RH Tip: Slide Duct to the right and remove.
NOTE
Refer to Fastener Notice .

Floor Air Outlet Duct Replacement - Right Side

  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screwdriver and a hammer.
  3. If equipped remove the HVAC module assembly screws.
  4. Remove the upper HVAC module case (1) from the lower HVAC module case (2).
  5. Remove the right temperature door (4) from the upper HVAC module case (3).
  1. Install the right temperature door (4) to the upper HVAC module case (3).
  2. Install the upper HVAC module case (1) to the lower HVAC module case (2).
  3. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  4. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer.
  3. If equipped remove the HVAC module assembly screws.
  4. Remove the upper HVAC module case (3) from the lower HVAC module case (10).
  5. Remove the air temperature separator plate (5) from the lower HVAC module case (10).
  6. Remove the left temperature door (11) from the lower HVAC module case (10).
  1. Install the left temperature door (11) to the lower HVAC module case (10).
  2. Install the air temperature separator plate (5) to the lower HVAC module case (10).
  3. Install the upper HVAC module case (3) to the lower HVAC module case (10).
  4. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  5. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screwdriver and a hammer.
  3. If equipped remove the HVAC module assembly screws.
  4. Separate the HVAC module assembly.
  5. Remove the mode actuator screws.
  6. Remove the mode actuator.
  7. Remove the mode actuator cam assembly.
  8. Remove the defroster door (8).
  1. Install the defroster door (8).
  2. Install the mode actuator cam assembly.
  3. Install the mode actuator.
  4. Install the mode actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  5. Install the HVAC module assembly halves.
  6. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  7. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screwdriver and a hammer.
  3. If equipped remove the HVAC module assembly screws.
  4. Separate the HVAC module assembly.
  5. Remove the air temperature separator plate (5) from the HVAC module assembly (10).
  6. Remove the lower mode door (9) from the HVAC module assembly (10).
  1. Install the lower mode door (9) to the HVAC module assembly (10).
  2. Install the air temperature separator plate (5) to the HVAC module assembly (10).
  3. Install the HVAC module assembly halves.
  4. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
IMPORTANTThe upper mode door (6) is serviced with the upper HVAC module case (3).
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .
  2. Disconnect the electrical connector (3) from the mode actuator (4).
  3. Remove the screws from the mode actuator (4).
  4. Remove the mode actuator (4) from the HVAC module assembly (1).
  5. If equipped remove the heat stakes (1) from the HVAC module (2) with a screwdriver and a hammer.
  6. If equipped remove the HVAC module assembly screws.
  7. Separate the HVAC module assembly.
  8. Remove the lever (7) from the upper mode door/upper HVAC module case (6).
  1. Install the lever (7) to the upper mode door/upper HVAC module case (6).
  2. Install the HVAC module assembly halves.
  3. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  4. Install the mode actuator to the HVAC module assembly.
  5. Install the screws to the mode actuator. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  6. Connect the electrical connector to the mode actuator.
  7. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-277995-S05259994912008012100000) .

Scheme 17

Scheme 17: Heater Core Cover Replacement
Scheme 17: Heater Core Cover Replacement
CalloutComponent Name
Preliminary Procedure: Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
1Heater Core Cover Screw NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2Heater Core Cover
NOTE
Refer to Fastener Notice .

Heater Core Cover Replacement

Scheme 18

Scheme 18: Heater Core Replacement
Scheme 18: Heater Core Replacement
CalloutComponent Name
Preliminary Procedure Remove the HVAC module. Refer to HVAC Module Assembly Replacement . Disconnect the wiring harness retainer from the heater core cover.
1Heater Core Cover Screw NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (14 lb in)
2Heater Core Cover Tighten: 1.5 N.m (14 lb in)
3Heater Core Pass Through Seal
4Heater Core
NOTE
Refer to Fastener Notice .

Heater Core Replacement

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