Home ReviewsRefund
Home/GMC/Sierra 3500 HD/GMC Sierra 3500 HD (2007-2012)/Repair manual/Automatic HVAC System/Heating, Ventilation and Air Conditioning: Removal & Instal…
Contents Wiring diagrams Section: Automatic HVAC System All sections

Heating, Ventilation and Air Conditioning: Removal & Installation GMC Sierra 3500 HD

Automatic HVAC System 19 illustrations ~5208 words

Balancing Procedure with Service Compressor Replacement (Flushing Not Required)

  1. Before installing the compressor, calculate the total amount of oil drained from the compressor and collected by the recovery equipment.
  2. If the amount drained and recorded is: LESS THAN 74 ml (2.5 ounces), leave 74 ml (2.5 ounces) in the replacement compressor. Do not drain the oil from the replacement compressor. MORE THAN 74 ml (2.5 ounces), calculate the difference between the amount that was drained and recorded. ADD the calculated difference to the A/C system by filling the A/C compressor or using J 45037: injector along with GE 48997: adapter.

Balancing Procedure with Service Compressor Replacement (Flushing Required)

  1. Flush the A/C system. Flushing will remove all the oil from the A/C system. Refer to «Flushing (Non HP2)»(ref-317146-S37692142512009060900000) or «Flushing (HP2)»(ref-317146-S40168315042009060900000) .
  2. Remove the A/C compressor from the vehicle. Refer to «Air Conditioning Compressor Replacement (LLY/LMM)»(ref-317146-S15129683832009060900000) , «Air Conditioning Compressor Replacement (LU3)»(ref-317146-S01954189142009060900000) , «Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG)»(ref-317146-S08426742152009060900000) or «Air Conditioning Compressor Replacement (HP2)»(ref-317146-S03372114022009060900000) . The A/C system must be replenished with 150 ml (5.0 oz.) of POE oil. NOTE: The refrigerant oil in the A/C system must be balanced during compressor replacement. The new service compressor is shipped with 74 ml (2.5 oz.) of refrigerant oil. Do not drain the oil from the compressor.
  3. Before installing the compressor, deduct the amount of oil shipped with the compressor 74 ml (2.5 oz.) from the total amount of the system oil 150 ml (5.0 oz.).
  4. Add the calculated amount 76 ml (2.5 oz.) of oil to the compressor and install it in the vehicle.

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  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 «Air Conditioning Compressor Oil Balancing (Non-HP2)»(ref-317146-S01463467332009060900000) or «Air Conditioning Compressor Oil Balancing (HP2)»(ref-317146-S08153080992009060900000) .

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-317257-S29937977602009060900000) .
  10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  11. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-317146-S38026048372009060900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  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 «Air Conditioning Compressor Oil Balancing (Non-HP2)»(ref-317146-S01463467332009060900000) or «Air Conditioning Compressor Oil Balancing (HP2)»(ref-317146-S08153080992009060900000) .
  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-317247-S12080742082009060900000) .
  8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  9. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-317146-S38026048372009060900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  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-317161-S40701625812009060900000) .
  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 «Air Conditioning Compressor Oil Balancing (Non-HP2)»(ref-317146-S01463467332009060900000) or «Air Conditioning Compressor Oil Balancing (HP2)»(ref-317146-S08153080992009060900000) .
  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 and tighten 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 «Air Conditioning System Seal Replacement»(ref-317146-S30361939602009060900000) .
  6. Install the A/C discharge hose bolt to the A/C compressor and tighten to 16 N.m (12 lb ft).
  7. Install the A/C suction hose to the compressor using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-317146-S30361939602009060900000) .
  8. Install the A/C suction hose bolt to the A/C compressor and tighten to 16 N.m (12 lb ft).
  9. Install the A/C drive belt. Refer to «Air Conditioning Compressor Belt Replacement (V8)»(ref-317192-S33781316762009060900000) .
  10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  11. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-317161-S40701625812009060900000) .
  12. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-317146-S38026048372009060900000) .

Scheme 4

Scheme 4: Air Conditioning Compressor Replacement (HP2)
Scheme 4: Air Conditioning Compressor Replacement (HP2)
CalloutComponent Name
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. CAUTION: This A/C system's high voltage A/C Compressor uses Polyolester (POE) refrigerant oil instead of Polyalkylene Glycol (PAG) refrigerant oil. Use only approved GM POE oil no more than two hours after removal from its sealed moisture proof packaging (reference GM POE label for proper usage) in refrigerant systems equipped with a High Voltage A/C compressor. GM POE oil is intended to be used with the J-45037 A/C oil injector and the GE-48997 A/C POE oil injector hose. Use of any refrigerant oil other than the approved GM POE, handled and installed per GM's requirements may result in compressor failure and/or loss of HV isolation with associated DTC's set. Preliminary Procedures Disable hybrid high voltage system. Refer to High Voltage Disabling and High Voltage Enabling . Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) or Refrigerant Recovery and Recharging (HP2) . Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove the suction hose. Refer to Suction Hose Replacement (LY2, LMF, L76 and L92) or Suction Hose Replacement (LMM) Remove the discharge hose. Refer to Discharge Hose Replacement (LMM) or Discharge Hose Replacement (LY2, LMF, L76 and L92) Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the engine shield. Refer to Engine Shield Replacement . Remove the oil pan skid plate. Refer to Oil Pan Skid Plate Replacement (2500/2500 with RPO NZZ) .
1A/C Compressor Cable Bolt (Qty: 2) CAUTION: High Voltage (HV) cables should never be removed from the mounting block. Removal of the individual HV cable from the mounting block may result in HV cable and/or component damage from improper: Cable sealing Electrical shielding Terminal position assurance CAUTION: Refer to Fastener Caution . Tighten: 9 N.m (80 lb in)
2A/C Compressor Cable Mounting Bolt (Qty: 2) Tighten: 9 N.m (80 lb in)
3A/C Compressor Cable
4A/C Compressor Seal Procedure: Remove and discard the seal.
5A/C Compressor Bolt (Qty: 3) Tighten: 50 N.m (37 lb ft)
6A/C Compressor Procedure Disconnect three wire low voltage electrical connector from compressor. Insert bottom compressor bolts into compressor before installing compressor to vehicle. Reprogram A/C compressor. Refer to Air Conditioning Compressor Control Module Programming and Setup Use only GM approved Polyolester (POE) oil. Failure to use the approved GM POE oil per GM's handling and installation requirements may result in compressor failure and/or loss of High Voltage isolation with the associated DTC's set. When replacing the A/C compressor, balance the compressor oil. Refer to Air Conditioning Compressor Oil Balancing (Non-HP2) or Air Conditioning Compressor Oil Balancing (HP2) Using J 39400: Electronic Halogen Leak Detector, leak test A/C compressor fittings. Special Tools: J 39400: Electronic Halogen Leak Detector
WARNING
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death.
CAUTION
This A/C system's high voltage A/C Compressor uses Polyolester (POE) refrigerant oil instead of Polyalkylene Glycol (PAG) refrigerant oil. Use only approved GM POE oil no more than two hours after removal from its sealed moisture proof packaging (reference GM POE label for proper usage) in refrigerant systems equipped with a High Voltage A/C compressor. GM POE oil is intended to be used with the J-45037 A/C oil injector and the GE-48997 A/C POE oil injector hose. Use of any refrigerant oil other than the approved GM POE, handled and installed per GM's requirements may result in compressor failure and/or loss of HV isolation with associated DTC's set.
CAUTION
High Voltage (HV) cables should never be removed from the mounting block. Removal of the individual HV cable from the mounting block may result in HV cable and/or component damage from improper: Cable sealing Electrical shielding Terminal position assurance
CAUTION
Refer to Fastener Caution .

Scheme 5

Scheme 5: Compressor Clutch Plate/Hub Assembly Replacement
Scheme 5: Compressor Clutch Plate/Hub Assembly Replacement
CalloutComponent Name
Preliminary Procedure Remove the air conditioning compressor belt. Refer to Air Conditioning Compressor Belt Replacement (V8) . Remove the air conditioning compressor if necessary. Refer to Air Conditioning Compressor Replacement (LLY/LMM) , Air Conditioning Compressor Replacement (LU3) , Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG) or Air Conditioning Compressor Replacement (HP2) . Disconnect the electrical connector from the air conditioning compressor.
1Air Conditioning Compressor Pulley Bolt CAUTION: Refer to Fastener Caution . Tighten: 18 N.m (13 lb ft)
2Air Conditioning Clutch Drive Plate Procedure: Measure and adjust the air conditioning compressor clutch drive plate per specification. Refer to Air Conditioning Clutch Drive Plate Adjustment .
3Air Conditioning Compressor Clutch Drive Plate Adjustment Shim
4Air Conditioning Compressor Clutch Pulley Snap Ring Procedure: Ensure the clutch pulley snap ring is installed with the flat side toward the air compressor. Note the rounded off portion of the snap ring per illustration, will be on the right side upon proper installation.
5Air Conditioning Compressor Clutch Pulley
6Air Conditioning Compressor Clutch Coil Snap Ring Procedure: Ensure the clutch coil snap ring is installed with the flat side toward the air compressor. Note the larger portion of the snap ring per illustration, will be on the right side upon proper installation.
7Air Conditioning Compressor Clutch Coil
CAUTION
Refer to Fastener Caution .
  1. Remove the A/C compressor. Refer to «Air Conditioning Compressor Replacement (LLY/LMM)»(ref-317146-S15129683832009060900000) , «Air Conditioning Compressor Replacement (LU3)»(ref-317146-S01954189142009060900000) , «Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG)»(ref-317146-S08426742152009060900000) or «Air Conditioning Compressor Replacement (HP2)»(ref-317146-S03372114022009060900000) .
  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 and tighten to 50 N.m (37 lb ft).
  3. Install the A/C belt tensioner.
  4. Install the A/C belt tensioner bolts and tighten to 50 N.m (37 lb ft).
  5. Install the A/C compressor. Refer to «Air Conditioning Compressor Replacement (LLY/LMM)»(ref-317146-S15129683832009060900000) , «Air Conditioning Compressor Replacement (LU3)»(ref-317146-S01954189142009060900000) , «Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG)»(ref-317146-S08426742152009060900000) or «Air Conditioning Compressor Replacement (HP2)»(ref-317146-S03372114022009060900000) .

Scheme 6

Scheme 6: Air Conditioning Compressor Bracket Replacement (HP2)
Scheme 6: Air Conditioning Compressor Bracket Replacement (HP2)
CalloutComponent Name
Preliminary Procedures Remove the air conditioning compressor. Refer to Air Conditioning Compressor Replacement (LLY/LMM) , Air Conditioning Compressor Replacement (LU3) , Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG) or Air Conditioning Compressor Replacement (HP2) . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the engine shield. Refer to Engine Shield Replacement . Remove the oil pan slid plate. Refer to Oil Pan Skid Plate Replacement (2500/2500 with RPO NZZ) . Remove transmission cooler bracket.
1A/C Compressor Bracket Bolt CAUTION: Refer to Fastener Caution . Tighten: 50 N.m (37 lb ft)
2A/C Compressor Bracket Bolt (Qty: 2) Tighten: 50 N.m (37 lb ft)
3A/C Compressor Bracket Bolt (Qty: 3) Tighten: 50 N.m (37 lb ft)
4A/C Compressor Bracket
CAUTION
Refer to Fastener Caution .
  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 (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  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-317133-S03180924612009060900000) .
  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-317133-S03180924612009060900000) .
  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 (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  9. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-317146-S38026048372009060900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  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-317133-S03180924612009060900000) .
  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. Install the discharge hose to the condenser using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-317146-S30361939602009060900000) .
  3. Install the discharge hose nut to the condenser and tighten to 16 N.m (12 lb ft).
  4. Install the upper air baffle. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-317133-S03180924612009060900000) .
  5. Connect the electrical connector to the A/C recirculation switch.
  6. Install the discharge hose (1) to the A/C compressor using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-317146-S30361939602009060900000) .
  7. Install the discharge hose mounting bolt and tighten to 16 N.m (12 lb ft).
  8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  9. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-317146-S38026048372009060900000) .

Scheme 7

Scheme 7: Suction Hose Replacement (LY2, LMF, L76 and L92)
Scheme 7: Suction Hose Replacement (LY2, LMF, L76 and L92)
CalloutComponent Name
Preliminary Procedure: Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) or Refrigerant Recovery and Recharging (HP2) .
1Suction Hose Bolt CAUTION: Refer to Fastener Caution . 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 Air Conditioning System Seal Replacement .
4A/C Suction Hose
CAUTION
Refer to Fastener Caution .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  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 (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  7. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-317146-S38026048372009060900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  2. Remove the upper radiator air baffle and deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-317133-S03180924612009060900000) .
  3. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-317159-S05750315452009060900000) .
  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 «Air Conditioning System Seal Replacement»(ref-317146-S30361939602009060900000) .
  2. Install the evaporator tube nut to the condenser and tighten 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 «Air Conditioning System Seal Replacement»(ref-317146-S30361939602009060900000) .
  4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped, and tighten to 16 N.m (12 lb ft).
  5. Install the evaporator tube to the evaporator.
  6. Install the evaporator tube nut to the evaporator and tighten 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-317159-S05750315452009060900000) .
  9. Install the upper radiator air baffle and deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-317133-S03180924612009060900000) .
  10. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  11. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-317146-S38026048372009060900000) .

Scheme 8

Scheme 8: Expansion (Orifice) Tube Replacement
Scheme 8: Expansion (Orifice) Tube Replacement
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) or Refrigerant Recovery and Recharging (HP2) . 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 CAUTION: Refer to Fastener Caution . 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 Air Conditioning O-Ring Seal Replacement .
3Orifice Tube Assembly Tip: Use J 26549-E to remove orifice tube. See Special Tools .
CAUTION
Refer to Fastener Caution .
  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 «Air Conditioning O-Ring Seal Replacement»(ref-317146-S26505729582009060900000) .
  2. Install the A/C low pressure switch to the accumulator and tighten 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-317146-S38026048372009060900000) .
  1. Disconnect the electrical connector from the A/C refrigerant pressure sensor.
  2. Remove the A/C refrigerant pressure sensor (1) from the condenser tube.
  1. Install the A/C refrigerant pressure sensor (1). Tighten: Tighten the switch to 6 N.m (53 lb in).
  2. Connect the electrical connector to the A/C refrigerant pressure sensor.
  3. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-317146-S38026048372009060900000) .
  4. Lower the vehicle.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  2. Remove tie bar. Refer to «Front End Upper Tie Bar Replacement»(ref-317155-S33730115652009060900000) .
  3. Remove the hood stop bracket. Refer to «Hood Stop Bracket Replacement»(ref-317155-S36182504542009060900000) .
  4. Remove radiator support bolts (1). Access the bolts from the rear of the upper radiator support.
  5. Remove radiator support.
  6. Remove the compressor discharge hose assembly bolt from the condenser.
  7. Disconnect the compressor discharge hose assembly from the condenser.
  8. Remove the evaporator tube nut from the condenser.
  9. Disconnect the evaporator tube from the condenser.
  10. Remove the insulator retainer bolts and the upper insulator retainers.
  11. 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 «Air Conditioning System Seal Replacement»(ref-317146-S30361939602009060900000) .
  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 «Air Conditioning System Seal Replacement»(ref-317146-S30361939602009060900000) .
  6. Install the compressor discharge hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  7. Install tie bar. Refer to «Front End Upper Tie Bar Replacement»(ref-317155-S33730115652009060900000) .
  8. Install the hood stop bracket. Refer to «Hood Stop Bracket Replacement»(ref-317155-S36182504542009060900000) .
  9. Install the radiator support. Access the bolts (1) from the rear of the upper radiator support. Refer to «Radiator Support Replacement»(ref-317155-S29737523402009060900000) . Tighten: Tighten the nut to 16 N.m (12 lb ft).
  10. Install radiator support bracket bolts (1).
  11. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  12. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-317146-S38026048372009060900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  2. Remove the fascia.
  3. Remove radiator support bolts (1). Access the bolts from the rear of the upper radiator support. Refer to «Radiator Support Replacement»(ref-317155-S29737523402009060900000) .
  4. Remove radiator support bracket bolts (1).
  5. Remove the compressor discharge hose assembly bolt from the condenser.
  6. Disconnect the compressor discharge hose assembly from the condenser.
  7. Remove the evaporator tube nut from the condenser.
  8. Disconnect the evaporator tube from the condenser.
  9. Remove the insulator retainer bolts and the upper insulator retainers.
  10. Remove the condenser from the vehicle.
  1. Install the condenser to the vehicle.
  2. Install the upper insulator retainers and the insulator retainer bolts and tighten to 2.4 N.m (21 lb in).
  3. Connect the evaporator tube to the condenser using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-317146-S30361939602009060900000) .
  4. Install the evaporator tube nut to the condenser and tighten to 16 N.m (12 lb ft).
  5. Connect the compressor discharge hose to the condenser using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-317146-S30361939602009060900000) .
  6. Install the compressor discharge hose nut to the condenser and tighten to 16 N.m (12 lb ft).
  7. Install the lower bolts to the hood latch support bracket and tighten 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-317155-S29737523402009060900000) . Tighten: Tighten the nut to 16 N.m (12 lb ft).
  9. Install radiator support bracket bolts (1).
  10. Install the fascia.
  11. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-317146-S04641835212009060900000) or «Refrigerant Recovery and Recharging (HP2)»(ref-317146-S08132353712009060900000) .
  12. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-317146-S38026048372009060900000) .

Scheme 9

Scheme 9: Air Conditioning Accumulator Replacement (Non-HP2)
Scheme 9: Air Conditioning Accumulator Replacement (Non-HP2)
CalloutComponent Name
Preliminary Procedure: Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) or Refrigerant Recovery and Recharging (HP2) .
1Suction Hose Nut CAUTION: Refer to Fastener Caution . Tip: Large A/C compressor hose to A/C evaporator. Tighten: 16 N.m (12 lb ft)
2A/C Suction Hose
3Sealing Washer Tip: Remove and discard sealing washer. Refer to Air Conditioning System Seal Replacement .
4Accumulator Mounting Bracket Nut Tighten: 16 N.m (12 lb ft)
5Accumulator Nut Tighten: 16 N.m (12 lb ft)
6Sealing Washer Tip: Remove and discard sealing washer. Refer to Air Conditioning System Seal 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 (Non-HP2) .
CAUTION
Refer to Fastener Caution .
  1. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Vac-N-Fill)»(ref-317133-S05947540392009060900000) or «Cooling System Draining and Filling (Static Fill)»(ref-317133-S04074773052009060900000) .
  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-317192-S34860146262009060900000) .
  5. Remove the battery. Refer to «Battery Replacement»(ref-317151-S20126381222009060900000) .
  6. Remove the accumulator. Refer to «Air Conditioning Accumulator Replacement (Non-HP2)»(ref-317146-S36694424482009060900000) .
  7. Remove the instrument panel to the service position. Refer to «Instrument Panel Service Positioning (without SLT)»(ref-317137-S09640146082009060900000) or «Instrument Panel Service Positioning (with SLT)»(ref-317137-S09032128172009060900000) .
  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. Refer to «Instrument Panel Service Positioning (without SLT)»(ref-317137-S09640146082009060900000) or «Instrument Panel Service Positioning (with SLT)»(ref-317137-S09032128172009060900000) .
  8. Install the upper intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-317192-S34860146262009060900000) .
  9. Install the battery. Refer to «Battery Replacement»(ref-317151-S20126381222009060900000) .
  10. Install the accumulator. Refer to «Air Conditioning Accumulator Replacement (Non-HP2)»(ref-317146-S36694424482009060900000) .
  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 (Vac-N-Fill)»(ref-317133-S05947540392009060900000) or «Cooling System Draining and Filling (Static Fill)»(ref-317133-S04074773052009060900000) .
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .
  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 «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Vac-N-Fill)»(ref-317133-S05947540392009060900000) or «Cooling System Draining and Filling (Static Fill)»(ref-317133-S04074773052009060900000) .
  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 (Vac-N-Fill)»(ref-317133-S05947540392009060900000) or «Cooling System Draining and Filling (Static Fill)»(ref-317133-S04074773052009060900000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Vac-N-Fill)»(ref-317133-S05947540392009060900000) or «Cooling System Draining and Filling (Static Fill)»(ref-317133-S04074773052009060900000) .
  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 (Vac-N-Fill)»(ref-317133-S05947540392009060900000) or «Cooling System Draining and Filling (Static Fill)»(ref-317133-S04074773052009060900000) .

Scheme 10

Scheme 10: Air Inlet Assembly Replacement
Scheme 10: Air Inlet Assembly Replacement
CalloutComponent Name
Preliminary Procedure Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Replacement . Disconnect the electrical connector from the recirculation actuator.
1Recirculation Actuator Screw (Qty: 2) CAUTION: Refer to Fastener Caution . 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.
CAUTION
Refer to Fastener Caution .

Scheme 11

Scheme 11: Blower Motor Control Module Replacement
Scheme 11: Blower Motor Control Module Replacement
CalloutComponent Name
Preliminary Procedure Remove the I/P insulator panel. Refer to Instrument Panel Insulator Replacement (With RPO SLT) or Instrument Panel Insulator Replacement (Without RPO SLT) . Disconnect the blower motor control module electrical connector.
1Blower Motor Control Module Screw (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2Blower Motor Control Module
CAUTION
Refer to Fastener Caution .
  1. If equipped, remove the sound insulator panel. Refer to «Instrument Panel Insulator Replacement (With RPO SLT)»(ref-317137-S33221161972009060900000) or «Instrument Panel Insulator Replacement (Without RPO SLT)»(ref-317137-S42638381372009060900000) .
  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 and tighten to 1.6 N.m (14 lb in).
  6. If equipped, install the sound insulator panel. Refer to «Instrument Panel Insulator Replacement (With RPO SLT)»(ref-317137-S33221161972009060900000) or «Instrument Panel Insulator Replacement (Without RPO SLT)»(ref-317137-S42638381372009060900000) .

Scheme 12

Scheme 12: Air Distributor Duct Replacement
Scheme 12: Air Distributor Duct Replacement
CalloutComponent Name
Preliminary Procedure: Remove the instrument panel to the service position. Refer to Instrument Panel Service Positioning (without SLT) or Instrument Panel Service Positioning (with SLT) .
1Air Distributor Bolts and Rivets (Qty: 6) CAUTION: Refer to Fastener Caution . Tighten: 2.5 N.m (16 lb in)
2Air Distributor Duct
CAUTION
Refer to Fastener Caution .

Scheme 13

Scheme 13: Side Window Air Outlet Replacement
Scheme 13: 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.

Scheme 14

Scheme 14: Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT)
Scheme 14: 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)

Scheme 15

Scheme 15: Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT)
Scheme 15: Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT)
CalloutComponent Name
1Instrument Panel Trim Plate Refer to Instrument Panel Trim Plate Replacement (Without RPO SLT)
2Instrument Panel Air Outlet Assembly - Left Tip: Release the retaining tabs securing the outlet to the instrument panel trim plate.

Scheme 16

Scheme 16: Instrument Panel Center Air Outlet Replacement (With RPO SLT)
Scheme 16: 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.

Scheme 17

Scheme 17: Instrument Panel Center Air Outlet Replacement (without RPO SLT)
Scheme 17: Instrument Panel Center Air Outlet Replacement (without RPO SLT)
CalloutComponent Name
1Instrument Panel Accessory Trim Plate Refer to Instrument Panel Accessory Trim Plate Replacement (with RPO SLT) or Instrument Panel Accessory Trim Plate Replacement (without 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.

Scheme 18

Scheme 18: Instrument Panel Outer Air Outlet Replacement - Right Side (Without RPO SLT)
Scheme 18: 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 (With RPO SLT) or Instrument Panel Upper Trim Panel Replacement (Without RPO SLT) .
2Instrument Panel Air Outlet Screw (Qty: 3) CAUTION: Refer to Fastener Caution . Tighten: 2 N.m (18 lb in)
3Instrument Panel Air Outlet Assembly - Right
CAUTION
Refer to Fastener Caution .

Scheme 19

Scheme 19: Instrument Panel Outer Air Outlet Replacement - Right Side (With RPO SLT)
Scheme 19: 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) CAUTION: Refer to Fastener Caution . 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)
CAUTION
Refer to Fastener Caution .
  1. Remove the push pin from the left floor air outlet duct (3).
  2. Remove the left floor duct (3) from the right floor air outlet duct (2).
  1. Install the left floor air outlet duct (3) to the right floor air outlet duct (2).
  2. Install the push pin to the left floor air outlet duct (3).

Scheme 20

Scheme 20: Floor Air Outlet Duct Replacement - Right Side
Scheme 20: Floor Air Outlet Duct Replacement - Right Side
CalloutComponent Name
Preliminary Procedure Remove the I/P insulator. Refer to Instrument Panel Insulator Replacement (With RPO SLT) or Instrument Panel Insulator Replacement (Without 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 CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2Air Outlet Duct - Floor RH Tip: Slide Duct to the right and remove.
CAUTION
Refer to Fastener Caution .
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .
  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 «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .
  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 «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .
  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 and tighten to 1.6 N.m (14 lb in).
  5. Install the HVAC module assembly halves.
  6. Install the screws to the HVAC module assembly and tighten to 1.6 N.m (14 lb in).
  7. Install the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .
  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. Refer to «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .

Note. The upper mode door is serviced with the upper HVAC module case.

  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .
  2. Disconnect the electrical connector from the mode actuator.
  3. Remove the screws from the mode actuator.
  4. Remove the mode actuator 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. Refer to «Air Conditioning and Heater Module Assembly Replacement»(ref-317146-S22644243452009060900000) .

Scheme 21

Scheme 21: Heater Core Cover Replacement
Scheme 21: Heater Core Cover Replacement
CalloutComponent Name
Preliminary Procedure: Remove the HVAC module. Refer to Air Conditioning and Heater Module Assembly Replacement .
1Heater Core Cover Screw CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2Heater Core Cover
CAUTION
Refer to Fastener Caution .

Scheme 22

Scheme 22: Heater Core Replacement
Scheme 22: Heater Core Replacement
CalloutComponent Name
Preliminary Procedure Remove the HVAC module. Refer to Air Conditioning and Heater Module Assembly Replacement . Disconnect the wiring harness retainer from the heater core cover.
1Heater Core Cover Screw CAUTION: Refer to Fastener Caution . 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
CAUTION
Refer to Fastener Caution .

More articles — Heating, Ventilation and Air Conditioning