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

Automatic HVAC System 40 illustrations ~9367 words

Installation Procedure

  1. Install the A/C compressor (2) to the A/C bracket (1).
  2. Install the A/C compressor mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  3. Connect the electrical connector to the A/C compressor.
  4. Install the A/C discharge hose to the compressor using new sealing washers. Refer to «Sealing Washer Replacement»(ref-184172-S36685995572005082200000) .
  5. Install the A/C discharge hose bolt to the A/C compressor. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  6. Install the A/C suction hose to the compressor using new sealing washers. Refer to «Sealing Washer Replacement»(ref-184172-S36685995572005082200000) .
  7. Install the A/C suction hose bolt to the A/C compressor. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  8. Install the intake air resonator replacement. Refer to «Intake Air Resonator Replacement»(ref-184137-S05331089022005082200000) in Engine Controls - 8.1L.
  9. Install the A/C drive belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-184189-S26537779342005082200000) in Engine Mechanical - 8.1L.
  10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  11. Leak test the fittings of the component using the J 39400-A .

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  2. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
  3. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
  4. Remove the A/C belt from the A/C compressor.
  5. Slowly release the tension on the A/C belt tensioner.
  6. Remove the right front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-184215-S06199612502005082200000) in Tires and Wheels.
  7. Remove the wheel house panel from the vehicle. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
  8. Remove the discharge hose bolt from the A/C compressor.
  9. Remove the discharge hose from the A/C compressor.
  10. Remove the suction hose bolt from the A/C compressor.
  11. Remove the suction hose from the A/C compressor.
  12. Discard the sealing washers. Cap all of the openings.
  13. Disconnect the electrical connections.
  14. Remove the A/C compressor mounting bolts. The lower right bolt (3) will stay with the compressor due to a lack of clearance.
  15. Remove the A/C compressor (2) from the bracket (1).
  16. If replacing the A/C compressor. Refer to «Compressor Oil Balancing»(ref-184172-S15883091112005082200000) .
  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-184172-S36685995572005082200000) .
  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-184172-S36685995572005082200000) .
  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 wheel house panel to the vehicle. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
  10. Install the right front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-184215-S06199612502005082200000) in Tires and Wheels.
  11. Install the A/C drive belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-184187-S42400643912005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
  12. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  13. Leak test the fittings of the component using the J 39400-A .

Scheme 37

Scheme 37
Scheme 37
  1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-184175-S17163319502005082200000) in General Information.
  2. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-184179-S32392415342005082200000) in Frame and Underbody.
  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. Refer to «Engine Protection Shield Replacement»(ref-184179-S32392415342005082200000) in Frame and Underbody.
  15. Lower the vehicle.
  1. Remove the A/C compressor. Refer to «Compressor Replacement (L18)»(ref-184172-S36134357292005082200000) , «Compressor Replacement (LB7)»(ref-184172-S08881900412005082200000) or «Compressor Replacement (LR4, LM7, and LQ4)»(ref-184172-S04348428702005082200000) .
  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 (L18)»(ref-184172-S36134357292005082200000) , «Compressor Replacement (LB7)»(ref-184172-S08881900412005082200000) or «Compressor Replacement (LR4, LM7, and LQ4)»(ref-184172-S04348428702005082200000) .
  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.

Scheme 38

Scheme 38: Installation Procedure
Scheme 38: Installation Procedure
  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.

Scheme 39

Scheme 39: Removal Procedure
Scheme 39: Removal 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. 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 Baffle and Deflector Replacement - Upper»(ref-184167-S28062100682005082200000) in Engine Cooling.
  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-184172-S07266075792005082200000) .
  9. Leak test the fittings of the component using the J 39400-A .
  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.
  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 Baffle and Deflector Replacement - Upper»(ref-184167-S28062100682005082200000) in Engine Cooling.
  6. Install the discharge hose (1) to the A/C compressor using new sealing washers.
  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-184172-S07266075792005082200000) .
  9. Leak test the fittings of the component using the J 39400-A .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  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-184172-S07266075792005082200000) .
  7. Leak test the fittings of the component using the J 39400-A .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  2. Remove the suction hose mounting bolt from the A/C compressor.
  3. Remove the suction hose (2) from the A/C compressor.
  4. Remove the suction hose nut from the accumulator.
  5. Remove the suction hose from the accumulator.
  6. Remove the suction hose assembly from the vehicle.
  7. Discard all of the used sealing washers. Cap the system openings.
  1. Install the suction hose to the vehicle.
  2. Install the suction hose to the accumulator using new sealing washers.
  3. Install the suction hose nut to the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  4. Install the suction hose (2) to the compressor using new sealing washers.
  5. Install the suction hose mounting bolt to the A/C compressor. 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-184172-S07266075792005082200000) .
  7. Leak test the fittings of the component using the J 39400-A .
  1. Install the evaporator tube to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-184172-S36685995572005082200000) .
  2. Install the evaporator tube nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  3. Install the grille to the vehicle. Refer to «Grille Replacement (GMC)»(ref-184169-S17598306392005082200000) or «Grille Replacement (Chevrolet)»(ref-184169-S35473267962005082200000) .
  4. Install the right park/turn signal lamp. Refer to «Park/Turn Signal Lamp Replacement (Old Style)»(ref-184117-S17387384182005082200000) .
  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. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  8. Leak test the fittings of the components using the J 39400-A .

Air Conditioning (A/C) Refrigerant Filter Installation

Tools Required: J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

IMPORTANTThe A/C Refrigerant filter, ACDelco P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing.

Scheme 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41
Scheme 41
  1. Remove the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-184141-S05694939612005082200000) in Engine Controls-4.3L or «Air Cleaner Assembly Replacement»(ref-184136-S32591068062005082200000) in Engine Controls-4.8L, 5.3L, and 6.0L or «Air Cleaner Assembly Replacement»(ref-184139-S29914489712005082200000) in Engine Controls-6.0L or «Air Cleaner Assembly Replacement»(ref-184137-S32230603092005082200000) in Engine Controls-8.1L.
  2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location.
  3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step.
  4. Using a tubing cutter, cut the marked section of the evaporator tube (2).
  5. Remove the burrs from the evaporator tube (2).
  6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1).
  7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves.
  8. Install the ferrules (3) with the small end toward the nut (4).
  9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator.
  10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten: Tighten the nuts to 15 N.m (11 lb ft).
  11. Remove the nuts (4) from the A/C refrigerant filter (1).
  12. Coat the O-rings (2) with 525 viscosity refrigerant oil.
  13. Install the O-rings (2) to the evaporator tube halves.
  14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten: Tighten the nuts to 15 N.m (11 lb ft).
  15. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  16. Leak test the fittings of the component using the J 39400-A .
  17. Install the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-184141-S05694939612005082200000) in Engine Controls-4.3L or «Air Cleaner Assembly Replacement»(ref-184136-S32591068062005082200000) in Engine Controls-4.8L, 5.3L, and 6.0L or «Air Cleaner Assembly Replacement»(ref-184139-S29914489712005082200000) in Engine Controls-6.0L or «Air Cleaner Assembly Replacement»(ref-184137-S32230603092005082200000) in Engine Controls-8.1L.
  1. Recover the refrigerant from the system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  2. Remove the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-184141-S05694939612005082200000) in Engine Controls-4.3L or «Air Cleaner Assembly Replacement»(ref-184136-S32591068062005082200000) in Engine Controls-4.8L, 5.3L, and 6.0L or «Air Cleaner Assembly Replacement»(ref-184139-S29914489712005082200000) in Engine Controls-6.0L or «Air Cleaner Assembly Replacement»(ref-184137-S32230603092005082200000) in Engine Controls-8.1L.
  3. Remove the nuts (4) from the A/C refrigerant filter (1).
  4. Remove the A/C refrigerant filter (3) from the evaporator tube (2).
  1. Coat the O-rings (2) with 525 viscosity refrigerant oil.
  2. Install the O-rings (2) to the evaporator tube.
  3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator.
  4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten: Tighten the nuts to 15 N.m (11 lb ft).
  5. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A .
  7. Install the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-184141-S05694939612005082200000) in Engine Controls-4.3L or «Air Cleaner Assembly Replacement»(ref-184136-S32591068062005082200000) in Engine Controls-4.8L, 5.3L, and 6.0L or «Air Cleaner Assembly Replacement»(ref-184139-S29914489712005082200000) in Engine Controls-6.0L or «Air Cleaner Assembly Replacement»(ref-184137-S32230603092005082200000) in Engine Controls-8.1L.

Expansion (Orifice) Tube Replacement

Tools Required

  1. J 26549-E Orifice Tube Remover. See «Special Tools and Equipment»(ref-184172-S42637868852005082200000) .
  2. J 39400-A Halogen Leak Detector. See «Special Tools and Equipment»(ref-184172-S42637868852005082200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  2. Loosen the nut from the evaporator tube fitting.
  3. Use the J 26549-E in order to remove the orifice tube (1) from the evaporator tube (2).
  4. Cap or plug the open line.
  1. Uncap or unplug the evaporator tube.
  2. Lubricate the new O-ring using new 525 viscosity refrigerant oil.
  3. Install the new O-ring seal.
  4. Install the orifice tube (1) to the evaporator tube (2). Coat the O-ring seal with 525 viscosity refrigerant oil. Insert the short screen end of the new orifice (1) into the evaporator tube.
  5. Connect the evaporator tube at the fitting. Tighten: Tighten the fitting to 25 N.m (18 lb ft).
  6. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  7. Leak test the fittings of the repaired component using J 39400-A .

Scheme 42

Scheme 42: Removal Procedure
Scheme 42: Removal Procedure
  1. Remove the cover from the underhood convenience center (1).
  2. Remove the compressor relay (2).
  1. Install the compressor relay (2).
  2. Install the cover to the underhood convenience center (1).
  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. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil.
  2. Install the NEW O-ring seal to the switch.
  3. Install the A/C low pressure switch to the accumulator. Tighten: Tighten the switch to 6 N.m (53 lb in).
  4. Connect the electrical connector to the A/C low pressure switch.
  5. Leak test the fittings of the components using the J 39400-A .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Disconnect the electrical connector from the A/C high pressure recirculation switch.
  3. Remove the A/C high pressure recirculation switch from the evaporator tube.
  1. Install the A/C high pressure recirculation switch. 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 .
  4. Lower 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.
  4. Install the evaporator tube nut to the condenser. Tighten: Tighten the evaporator tube nut to 16 N.m (12 lb ft).
  5. Connect the compressor discharge hose to the condenser using new sealing washers.
  6. Install the compressor discharge hose nut to the condenser Tighten: Tighten the compressor discharge hose nut to 16 N.m (12 lb ft).
  7. Install the lower bolts to the hood latch support bracket. Tighten: Tighten the compressor discharge hose nut to 9 N.m (80 lb in).
  8. Install the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support. Tighten: Tighten the compressor discharge hose nut to 9 N.m (80 lb in).
  9. Install the grille. Refer to «Grille Replacement (GMC)»(ref-184169-S17598306392005082200000) or «Grille Replacement (Chevrolet)»(ref-184169-S35473267962005082200000) in Exterior Trim.
  10. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  11. Leak test the fittings of the component using the J 39400-A .
  1. Install new O-ring seals. Refer to «O-Ring Replacement»(ref-184172-S25049215342005082200000) .
  2. Install the retaining bracket (6) to the accumulator.
  3. Install the retaining bracket bolt (5). Tighten: Tighten the bolt to 10 N.m (89 lb in).
  4. Install the accumulator (3).
  5. Install the accumulator bracket nut (4). Tighten: Tighten the nut to 9 N.m (80 lb in).
  6. Install the nut (2) to the evaporator fitting. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  7. Install the compressor hose to the accumulator.
  8. Install the compressor hose nut to the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  9. Connect the electrical connector to the A/C low pressure switch.
  10. Install the nut to the evaporator tube (3). Tighten: Tighten the nut to 25 N.m (18 lb ft).
  11. Install the evaporator tube to the evaporator.
  12. Install the evaporator tube nut to the evaporator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  13. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  14. Leak test the fittings of the component using the J 39400-A .
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. If equipped remove the auxiliary battery. Refer to «Battery Replacement - Auxiliary»(ref-184144-S18225513442005082200000) in Engine Electrical.
  3. 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.
  4. 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.
  5. Remove the accumulator. Refer to «Accumulator Replacement»(ref-184172-S14312163082005082200000) .
  6. Remove the instrument panel carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-184121-S14907095842005082200000) in Instrument Panel, Gages and Console.
  7. Remove the HVAC module drain hose.
  8. Disconnect the electrical harnesses and the ground connections from the HVAC module.
  9. Remove the nuts (4) from the HVAC module (2).
  10. Remove the bolts (3) from the HVAC module (2).
  11. Remove the HVAC module (2) from the vehicle (1).

Scheme 43

Scheme 43: Installation Procedure
Scheme 43: Installation Procedure

Scheme 44

Scheme 44
Scheme 44
  1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary.
  2. Install the HVAC module (2) to the vehicle (1).
  3. Install the nuts (4) to the HVAC module (2). Tighten: Tighten the nuts to 9 N.m (80 lb in).
  4. Install the bolts (4) to the HVAC module (2). Tighten: Tighten the bolts to 4 N.m (35 lb in).
  5. Connect the electrical harnesses and the ground connections.
  6. Install the HVAC module drain hose.
  7. Install the instrument panel carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-184121-S14907095842005082200000) in Instrument Panel, Gages and Console.
  8. Install the accumulator. Refer to «Accumulator Replacement»(ref-184172-S14312163082005082200000) .
  9. 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.
  10. 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.
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .
  2. Remove the heater/vent module screws.
  3. Separate the heater/vent module.
  4. Remove the evaporator core from the heater/vent module.
  1. Install the evaporator core to the heater/vent module.
  2. Install the heater/vent module halves.
  3. Install the heater/vent module screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  4. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .
  5. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
  6. Leak test the fittings of the component using the J 39400-A .
  1. Install the inlet heater hose.
  2. Install the inlet heater hose (1) to the engine coolant inlet fitting.
  3. Connect the heater and surge tank hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  4. Install the heater and surge tank hose to the mounting clip.
  5. Install the air intake tube.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Install the heater hose.
  2. Connect the auxiliary inlet heater hose if equipped.
  3. Install the inlet heater hose (1) to the engine coolant outlet.
  4. Reposition the inlet heater hose clamp to the engine coolant outlet.
  5. Connect the heater and surge tank hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  6. Install the heater and surge tank hose to the mounting clip.
  7. Install the air intake tube.
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Remove the air intake tube.
  3. Remove the heater and surge tank hose from the mounting clip.
  4. Using the J 43181 disconnect the heater hose from the heater core inlet. 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 hose from the heater core.
  5. Remove the inlet heater hose from the engine.
  6. Remove the inlet heater hose.

Scheme 45

Scheme 45: Installation Procedure
Scheme 45: Installation Procedure
  1. Install the inlet heater hose.
  2. Install the inlet heater hose to the engine.
  3. Connect the heater and surge tank hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  4. Install the heater and surge tank hose to the mounting clip.
  5. Install the air intake tube.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Install the inlet heater hose (6) to the auxiliary water pump (1).
  2. Position the inlet heater hose clamp (4) to the auxiliary water pump (1).
  3. Install the inlet heater hose to the engine.
  4. Position the inlet heater hose clamp to the engine.
  5. Install the air cleaner outlet duct.
  6. Install the radiator inlet hose clip to the outlet duct.
  7. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the screws to 7 N.m (62 lb in).
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Using the J 43181 disconnect the heater hose from the heater core inlet. 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 hose from the heater core.
  3. Reposition the inlet heater hose clamp (2) from the auxiliary water pump (1).
  4. Remove the inlet heater hose (3) from the auxiliary water pump (1).
  1. Install the inlet heater hose (3) to the auxiliary water pump (1).
  2. Position the inlet heater hose clamp (2) to the auxiliary water pump (1).
  3. Connect the inlet heater hose to the heater core.
  4. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Remove the air intake tube.
  3. Remove the heater and surge tank hose from the mounting clip.
  4. Using the J 43181 disconnect the heater hose from the heater core outlet. 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 hose from the heater core.
  5. Remove the outlet heater hose nut (2) from the engine. Discard the nut.
  6. Remove the outlet heater hose bolt (3) from the engine. Discard the bolt.
  7. Remove the auxiliary outlet heater hose if equipped.
  8. Remove the outlet heater hose from the outlet pipe assembly.
  9. Remove the outlet heater hose.
  1. Install the outlet heater hose.
  2. Install the outlet heater hose to the outlet pipe assembly.
  3. Install the auxiliary outlet heater hose if equipped.
  4. Install the NEW outlet heater hose nut (2) and bolt (3) to the engine. Tighten: Tighten the nut and bolt to 25 N.m (18 lb ft).
  5. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  6. Install the outlet heater hose to the mounting clip.
  7. Install the air intake tube.
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Remove the air intake tube.
  3. Remove the heater and surge tank hose from the mounting clip.
  4. Using the J 43181 disconnect the heater hose from the heater core outlet. 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 hose from the heater core.
  5. Remove the outlet heater hose from the engine.
  6. Remove the outlet heater hose.
  1. Install the outlet heater hose.
  2. Install the outlet heater hose to the engine.
  3. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  4. Install the heater and surge tank hose to the mounting clip.
  5. Install the air intake tube.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Remove the air intake tube.
  3. Using the J 43181 disconnect the heater hose from the heater core outlet. 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 hose from the heater core.
  4. Remove the outlet heater hose from the engine.
  5. Remove the outlet heater hose mounting bolt.
  6. Remove the outlet heater hose from the engine.
  7. Remove the outlet heater hose.
  1. Install the heater hose.
  2. Install the outlet heater hose to the engine.
  3. Install the outlet heater hose mounting bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  4. Connect the heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  5. Install the air intake tube.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. If equipped, remove the IP sound insulator. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-184121-S21056577922005082200000) in Instrument Panel, Gages, and Console.
  2. Disconnect the electrical connection from the blower motor.
  3. Disconnect the electrical connection from the blower motor resistor.
  4. Remove the blower motor resistor retaining screws.
  5. Remove the blower motor resistor.

Scheme 46

Scheme 46: Installation Procedure
Scheme 46: Installation Procedure

Scheme 47

Scheme 47
Scheme 47
  1. Install the blower motor resistor.
  2. Install the blower motor resistor retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Connect the electrical connection to the blower motor resistor.
  4. Connect the electrical connection to the blower motor.
  5. If equipped, install the IP sound insulator. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-184121-S21056577922005082200000) in Instrument Panel, Gages, and Console.
  1. If equipped, remove the sound insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-184121-S21056577922005082200000) in Instrument Panel, Gages, and Console.
  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 «Insulator Replacement - Instrument Panel (I/P)»(ref-184121-S21056577922005082200000) in Instrument Panel, Gages, and Console.

Scheme 48

Scheme 48: Removal Procedure
Scheme 48: Removal Procedure
  1. Remove the sound insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-184121-S21056577922005082200000) in Instrument Panel, Gages, and Console.
  2. Disconnect the electrical connector (2) from the blower motor (1).
  3. Remove the screws from the blower motor (1).
  4. Remove the blower motor (1) from the HVAC module (3).
  5. Remove the retainer from the blower motor impeller. Discard the retainer.
  6. Remove the blower motor impeller from the blower motor (1).
  1. Install the blower motor impeller to the blower motor (1).
  2. Install the new retainer to the blower motor impeller.
  3. Install the blower motor (1) to the HVAC module (3).
  4. Install the screws to the blower motor (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Connect the electrical connector (2) to the blower motor (1).
  6. Install the sound insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-184121-S21056577922005082200000) in Instrument Panel, Gages, and Console.
  1. Remove the sound insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-184121-S21056577922005082200000) in Instrument Panel, Gages, and Console.
  2. Disconnect the electrical connector (2) from the blower motor (1).
  3. Remove the screws from the blower motor (1).
  4. Remove the blower motor (1) from the HVAC module (3).
  5. Remove the retainer from the blower motor impeller. Discard the retainer.
  6. Remove the blower motor impeller from the blower motor (1).
  1. Install the blower motor impeller to the blower motor (1).
  2. Install the new retainer to the blower motor impeller.
  3. Install the blower motor (1) to the HVAC module (3).
  4. Install the screws to the blower motor (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Connect the electrical connector (2) to the blower motor (1).
  6. Install the sound insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-184121-S21056577922005082200000) in Instrument Panel, Gages, and Console.
  1. Remove the IP carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-184121-S14907095842005082200000) in Instrument Panel, Gages and Console.
  2. Remove the air distribution duct retaining screws.
  3. Remove the air distribution duct.

Scheme 49

Scheme 49: Installation Procedure
Scheme 49: Installation Procedure
  1. Install the air distribution duct.
  2. Install the air distribution duct retaining screws.
  3. Tighten the screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  4. Install the IP carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-184121-S14907095842005082200000) in Instrument Panel, Gages and Console.
  1. Remove the instrument panel (I/P) bezel. Refer to «Bezel Replacement - Instrument Panel (I/P) Cluster»(ref-184121-S08288480992005082200000) in Instrument Panel, Gages, and Console.
  2. Remove the knee bolster. Refer to «Knee Bolster Replacement»(ref-184121-S33691865652005082200000)
  3. Remove the air deflector housing from the I/P by prying it out.
  4. Disconnect the electrical connectors.
  5. Remove the air deflector screws.
  6. Remove the air deflector from the housing.

Scheme 50

Scheme 50: Installation Procedure
Scheme 50: Installation Procedure
  1. Install the air deflector to the housing.
  2. Install the retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Connect the electrical connectors.
  4. Install the air deflector assembly to the I/P.
  5. Remove the knee bolster. Refer to «Knee Bolster Replacement»(ref-184121-S33691865652005082200000) .
  6. Install the I/P bezel. Refer to «Bezel Replacement - Instrument Panel (I/P) Cluster»(ref-184121-S08288480992005082200000) in Instrument Panel, Gages, and Console.
  1. Remove the instrument panel (I/P) bezel. Refer to «Bezel Replacement - Instrument Panel (I/P) Cluster»(ref-184121-S08288480992005082200000) in Instrument Panel, Gages, and Console.
  2. Remove the I/P trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(ref-184121-S09813216512005082200000) in Instrument Panel, Gages, and Console.
  3. Remove the deflector mounting screws.
  4. Remove the deflector from the I/P.
  1. Install the deflector to the I/P.
  2. Install the deflector mounting screws. Tighten: Tighten the screw to 1.6 N.m (14 lb in).
  3. Install the I/P trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(ref-184121-S09813216512005082200000) in Instrument Panel, Gages, and Console.
  4. Install the I/P bezel. Refer to «Bezel Replacement - Instrument Panel (I/P) Cluster»(ref-184121-S08288480992005082200000) in Instrument Panel, Gages, and Console.

Scheme 51

Scheme 51: Removal Procedure
Scheme 51: Removal Procedure
  1. Use a flat blade tool in order to remove the deflector from the instrument panel.
  2. Remove the deflector.
  1. Align the deflector into the opening in the instrument panel.
  2. Push the deflector into the instrument panel until the deflector snaps into place.

Scheme 52

Scheme 52: Removal Procedure
Scheme 52: Removal Procedure
  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.
  1. Remove the right closeout/insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-184121-S21056577922005082200000) in Instrument Panel, Gages, and Console.
  2. Remove the screw from the right floor air outlet duct (3).
  3. Remove the right floor air outlet duct (3) from the HVAC module (2).
  1. Install the right floor air outlet duct (3) to the HVAC module (2).
  2. Install the screw to the right floor air outlet duct (3). Tighten: Tighten the screw to 1.6 N.m (14 lb in).
  3. Install the right closeout/insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-184121-S21056577922005082200000) in Instrument Panel, Gages, and Console.

Scheme 53

Scheme 53: Removal Procedure
Scheme 53: Removal Procedure
  1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .
  2. Remove the heater/vent module screws.
  3. Separate the heater/vent module halves.
  4. Remove the air temperature door (8).
  1. Install the air temperature door (8).
  2. Assemble the heater/vent module halves.
  3. Install the heater/vent module screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  4. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .

Scheme 54

Scheme 54: Removal Procedure
Scheme 54: Removal Procedure

Scheme 55

Scheme 55
Scheme 55

Scheme 56

Scheme 56
Scheme 56

Scheme 57

Scheme 57
Scheme 57

Scheme 58

Scheme 58
Scheme 58
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  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 (1).
  5. Remove the wiring harness from the air distribution housing (1).
  6. Remove the screws from the air distribution housing (1).
  7. Remove the air distribution housing (1) from the HVAC module (2).
  8. Remove the screws from the upper recirculation housing (1).
  9. Remove the upper recirculation housing (1) from the HVAC module (2).
  10. Remove the screws from the lower recirculation housing (1).
  11. Remove the lower recirculation housing (1) from the HVAC module (2).
  12. Remove the wiring harness from the HVAC module.
  13. Remove the screws from the HVAC module.
  14. Remove the upper HVAC module case (1) from the lower HVAC module case (2).
  15. Remove the right temperature door (2) from the upper HVAC module case (1).
  1. Install the right temperature door (2) to the upper HVAC module case (1).
  2. Install the upper HVAC module case (1) to the lower HVAC module case (2).
  3. Install the screws to the HVAC module. Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Install the wiring harness to the HVAC module.
  5. Install the lower recirculation housing (1) to the HVAC module (2).
  6. Install the screws to the lower recirculation housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  7. Install the upper recirculation housing (1) to the HVAC module (2).
  8. Install the screws to the upper recirculation housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  9. Install the air distribution housing (1) to the HVAC module (2).
  10. Install the screws to the air distribution housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  11. Install the wiring harness to the air distribution housing (1).
  12. Install the mode actuator (4) to the HVAC module (1).
  13. Install the screws to the mode actuator (4). Tighten: Tighten the screws to 2 N.m (18 lb in).
  14. Connect the electrical connector (3) to the mode actuator (4).
  15. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .

Scheme 59

Scheme 59: Removal Procedure
Scheme 59: Removal Procedure

Scheme 60

Scheme 60
Scheme 60
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  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 (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-184172-S39854938532005082200000) .

Scheme 61

Scheme 61
Scheme 61
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  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 (1).
  5. Remove the wiring harness from the air distribution housing (1).
  6. Remove the screws from the air distribution housing (1).
  7. Remove the air distribution housing (1) from the HVAC module (2).
  8. Remove the screws from the upper recirulation housing (1).
  9. Remove the upper recirulation housing (1) from the HVAC module (2).
  10. Remove the screws from the lower recirulation housing (1).
  11. Remove the lower recirulation housing (1) from the HVAC module (2).
  12. Remove the wiring harness from the HVAC module.
  13. Remove the screws from the HVAC module.
  14. Remove the upper HVAC module case (1) from the lower HVAC module case (2).
  15. Remove the HVAC module chamber plate (1) from the lower HVAC module case (3).
  16. Remove the left temperature door (2) from the lower HVAC module case (3).
  1. Install the left temperature door (2) to the lower HVAC module case (3).
  2. Install the HVAC module chamber plate (1) to the lower HVAC module case (3).
  3. Install the upper HVAC module case (1) to the lower HVAC module case (2).
  4. Install the screws to the HVAC module. Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the wiring harness to the HVAC module.
  6. Install the lower recirulation housing (1) to the HVAC module (2).
  7. Install the screws to the lower recirulation housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  8. Install the upper recirulation housing (1) to the HVAC module (2).
  9. Install the screws to the upper recirulation housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  10. Install the air distribution housing (1) to the HVAC module (2).
  11. Install the screws to the air distribution housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  12. Install the wiring harness to the air distribution housing (1).
  13. Install the mode actuator (4) to the HVAC module (1).
  14. Install the screws to the mode actuator (4). Tighten: Tighten the screws to 2 N.m (18 lb in).
  15. Connect the electrical connector (3) to the mode actuator (4).
  16. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  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-184172-S39854938532005082200000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  2. Remove the HVAC module assembly screws.
  3. Separate the HVAC module assembly.
  4. Remove the mode actuator screws.
  5. Remove the mode actuator (3).
  6. Remove the mode actuator cam assembly (4).
  7. Remove the defroster door lever (2).
  8. Remove the defroster door (1).
  1. Install the defroster door (1).
  2. Install the defroster door lever (2).
  3. Install the mode actuator cam assembly (4).
  4. Install the mode actuator (3).
  5. Install the mode actuator screws.
  6. Install the mode actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  7. Install the HVAC module assembly halves.
  8. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  9. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  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. 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-184172-S39854938532005082200000) .
  1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .
  2. Remove the heater/vent module screws.
  3. Separate the heater/vent module.
  4. Remove the mode actuator screws.
  5. Remove the mode actuator (3).
  6. Remove the mode actuator cam assembly (4).
  7. Remove the defroster door lever (2).
  8. Remove the defroster door (1).
  1. Install the defroster door (1).
  2. Install the defroster door lever (2).
  3. Install the mode actuator cam assembly (4).
  4. Install the mode actuator (3).
  5. Install the mode actuator screws.
  6. Install the mode actuator screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  7. Install the heater/vent module halves.
  8. Install the screws to the heater/vent module. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  9. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .

Scheme 62

Scheme 62
Scheme 62
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  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. Remove the wiring harness from the air distribution housing (1).
  6. Remove the screws from the air distribution housing (1).
  7. Remove the air distribution housing (1) from the HVAC module assembly (2).
  8. Remove the mode door (2) from the air distribution housing (1).
  1. Install the mode door (1) to the air distribution housing (1).
  2. Install the air distribution housing (1) to the HVAC module assembly (2).
  3. Install the screws to the air distribution housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Install the wiring harness to the air distribution housing (1).
  5. Connect the electrical connector (3) to the mode actuator (4).
  6. Install the screws to the mode actuator (4).
  7. Install the mode actuator (4) to the HVAC module assembly (1).
  8. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  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. 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-184172-S39854938532005082200000) .

Scheme 63

Scheme 63
Scheme 63

Scheme 64

Scheme 64
Scheme 64
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  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. Remove the wiring harness from the air distribution housing (1).
  6. Remove the screws from the air distribution housing (1).
  7. Remove the air distribution housing (1) from the HVAC module assembly (2).
  8. Remove the screws from the air distribution housing (1).
  9. Separate the air distribution housing halves.
  10. Remove the lever from the upper mode door (4).
  11. Remove the lever from the defrost door (2).
  12. Remove the door assembly (3) from the left air distribution housing (1).
  13. Remove the mode door (4) from the door assembly (3).
  1. Install the mode door (4) to the door assembly (3).
  2. Install the door assembly (3) to the left air distribution housing (1).
  3. Install the lever to the defrost door (2).
  4. Install the lever to the upper mode door (4).
  5. Install the air distribution housing halves.
  6. Install the screws to the air distribution housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  7. Install the air distribution housing (1) to the HVAC module assembly (2).
  8. Install the screws to the air distribution housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  9. Install the wiring harness to the air distribution housing (1).
  10. Connect the electrical connector (3) to the mode actuator (4).
  11. Install the mode actuator (4) to the HVAC module assembly (1).
  12. Install the screws to the mode actuator (4). Tighten: Tighten the screws to 2 N.m (18 lb in).
  13. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
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-184172-S39854938532005082200000) .
  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 screw driver 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-184172-S39854938532005082200000) .

Scheme 65

Scheme 65: Removal Procedure
Scheme 65: Removal Procedure

Scheme 66

Scheme 66
Scheme 66

Scheme 67

Scheme 67
Scheme 67
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  2. Remove the wiring harness from the recirculation housing (1).
  3. Remove the screws from the upper recirculation housing (1).
  4. Remove the upper recirculation housing (1) from the HVAC module assembly (2).
  5. Disconnect the electrical connector from the recirculation actuator (1).
  6. Remove the screws from the recirculation actuator (1).
  7. Remove the recirculation actuator (1) from the recirculation housing (2).
  8. Remove the recirculation door (1) from the recirculation housing (2).
  1. Install the recirculation door (1) to the recirculation housing (2).
  2. Install the recirculation actuator (1) to the recirculation housing (2).
  3. Install the screws to the recirculation actuator (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Connect the electrical connection to the recirculation actuator (1).
  5. Install the upper recirculation housing (1) to the HVAC module assembly (2).
  6. Install the screws to the upper recirculation housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  7. Install the wiring harness to the recirculation housing (1).
  8. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .

Scheme 68

Scheme 68: Removal Procedure
Scheme 68: Removal Procedure

Scheme 69

Scheme 69
Scheme 69

Scheme 70

Scheme 70
Scheme 70
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  2. Disconnect the recirculation actuator electrical connection (1).
  3. Remove the recirculation actuator mounting screws.
  4. Remove the recirculation actuator.
  5. Remove the recirculation door.
  1. Install the recirculation door.
  2. Install the recirculation actuator.
  3. Install the recirculation actuator mounting screws. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  4. Connect the recirculation actuator electrical connection (1).
  5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .
  2. Disconnect the recirculation actuator electrical connection (1).
  3. Remove the recirculation actuator mounting screws.
  4. Remove the recirculation actuator.
  5. Remove the recirculation door.
  1. Install the recirculation door.
  2. Install the recirculation actuator.
  3. Install the recirculation actuator mounting screws. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  4. Connect the recirculation actuator electrical connection (1).
  5. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .
  1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .
  2. Remove the heater/vent module screws.
  3. Separate the heater/vent module.
  4. Remove the mode actuator (3).
  5. Remove the mode actuator cam assembly (4).
  6. Remove the heater door cam assembly (5).
  7. Remove the heater door (6).
  1. Remove the heater door (6).
  2. Install the heater door cam assembly (5).
  3. Install the mode actuator cam assembly (4).
  4. Install the mode actuator (3).
  5. Install the heater/vent module halves.
  6. Install the heater/vent module screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  7. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .

Scheme 71

Scheme 71: Removal Procedure
Scheme 71: Removal Procedure

Scheme 72

Scheme 72
Scheme 72
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  2. Remove the screws from the heater core cover.
  3. Remove the heater core cover (1) from the HVAC module assembly (2).
  4. Remove the heater core cowl gasket (1) from the heater core (2).
  5. Remove the heater core (1) from the HVAC module assembly (2).

Scheme 73

Scheme 73: Installation Procedure
Scheme 73: Installation Procedure
  1. Install the heater core (1) to the HVAC module assembly (2).
  2. Install the heater core cowl gasket (1) to the HVAC module assembly (2).
  3. Install the heater core cover (1) to the HVAC module assembly (2).
  4. Install the screws to the heater core cover (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .

Scheme 74

Scheme 74: Removal Procedure
Scheme 74: Removal Procedure
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  2. Remove the screws from the heater core cover.
  3. Remove the heater core cover (1) from the HVAC module assembly (2).
  4. Remove the heater core cowl gasket (1) from the heater core (2).
  5. Remove the heater core (2) from the HVAC module assembly (3).
  1. Install the heater core (2) to the HVAC module assembly (3).
  2. Install the heater core cowl gasket (1) to the heater core (2).
  3. Install the heater core cover (1) to the HVAC module assembly (2).
  4. Install the screws to the heater core cover (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-184172-S39854938532005082200000) .
  1. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .
  2. Remove the heater core cover screws.
  3. Remove the heater core cover.
  4. Remove the heater core.

Scheme 75

Scheme 75: Installation Procedure
Scheme 75: Installation Procedure
  1. Install the heater core.
  2. Install the heater core cover.
  3. Install heater core cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  4. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-184172-S02277479602005082200000) .
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. If equipped remove the auxiliary battery. Refer to «Battery Replacement - Auxiliary»(ref-184144-S18225513442005082200000) in Engine Electrical.
  3. Reposition the inlet heater hose clamp from the heater core.
  4. Remove the inlet heater hose from the heater core.
  5. Reposition the outlet heater hose clamp from the heater core.
  6. Remove the outlet heater hose from the heater core.
  7. Remove the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-184121-S14907095842005082200000) in Instrument Panel, Gages and Console.
  8. Remove the heater/vent module drain hose.
  9. Disconnect the electrical harnesses and the ground connections.
  10. Remove the heater/vent module mounting nuts and the screws.
  11. Remove the heater/vent module assembly from the vehicle.

Scheme 76

Scheme 76: Installation Procedure
Scheme 76: Installation Procedure
  1. Install the heater/vent module assembly to the vehicle.
  2. Install the heater/vent module mounting nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  3. Install the heater/vent module mounting screws. Tighten: Tighten the screws to 4 N.m (35 lb in).
  4. Connect the electrical harnesses and the ground connections.
  5. Install the heater/vent module drain hose.
  6. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-184121-S14907095842005082200000) in Instrument Panel, Gages and Console.
  7. Install the outlet heater hose to the heater core.
  8. Reposition the outlet heater hose clamp to the heater core.
  9. Install the inlet heater hose to the heater core.
  10. Reposition the inlet heater hose clamp to the heater core.
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.

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