Home ReviewsRefund
Home/GMC/Sierra/GMC Sierra III (2013-2015)/Repair manual/Automatic HVAC System/Heating, Ventilation, and Air Conditioning: Removal & Insta…
Contents Wiring diagrams Section: Automatic HVAC System All sections

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

Automatic HVAC System 29 illustrations ~4836 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 sum of the amount of oil drained from the removed compressor and the amount of oil removed during refrigerant recovery is: LESS THAN 40 ml (1.4 ounces), no balancing is required. Install the replacement compressor as is. It contains 40 ml (1.4 ounces) of PAG oil. MORE THAN 40 ml (1.4 ounces), additional oil is required. Subtract 40 ml (1.4 oz) from the sum of removed oil (oil drained + oil recovered). ADD the calculated difference to the A/C compressor or by filling the A/C system using J 45037 injector.

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»(ref-651014-S42649624392014081900000) .
  2. Remove the A/C compressor from the vehicle. Refer to «Air Conditioning Compressor Replacement (LV3)»(ref-651014-S12955681432014081900000) , «Air Conditioning Compressor Replacement (L83)»(ref-651014-S30971541712014081900000) . The A/C system must be replenished with 100 ml (3.4 oz) of PAG oil. NOTE: The refrigerant oil in the A/C system must be balanced during compressor replacement. The new service compressor is shipped with 40 ml (1.4 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 40 ml (1.4 oz) from the total amount of the system oil 100 ml (3.4 oz).
  4. Add the calculated amount 60 ml (2.0 oz) of oil to the A/C compressor or by filling the A/C system using J 45037 injector.

Air Conditioning Clutch Assembly Replacement (L83)

CalloutComponent Name
Preliminary Procedure Remove the air conditioning compressor belt. Refer to Air Conditioning Compressor Belt Replacement . Remove the air conditioning compressor if necessary. Refer to Air Conditioning Compressor Replacement (LV3) , Air Conditioning Compressor Replacement (L83) . 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 .

Air Conditioning Clutch Assembly Replacement (L83)

Removal Procedure

  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.

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.
  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 refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-651029-S17583717992014081900000) .
  3. Remove the air conditioning condenser hose from the compressor and position out of the way. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  4. Remove the air conditioning tube bracket bolt (1) from the generator and drive belt tensioner bracket.
  5. Remove the air conditioning compressor hose (2) from the air conditioning compressor.
  6. Remove and discard the old sealing washer (3) from the air conditioning compressor hose (2).
  7. Remove the air conditioning compressor hose nut (1) from the air conditioning evaporator thermal expansion valve.
  8. Remove the air conditioning compressor hose (2) from the air conditioning evaporator thermal expansion valve.
  9. Remove and discard the old sealing washer (3) from the air conditioning compressor hose (2).
  1. Install NEW sealing washer (3) to the air conditioning compressor hose (2). Refer to «Air Conditioning System Seal Replacement»(ref-651014-S07405085332014081900000) .
  2. Install the air conditioning compressor hose (2) to the vehicle.
  3. Install the air conditioning compressor hose (2) to the air conditioning evaporator thermal expansion valve.
  4. Install the air conditioning compressor hose nut (1) to the air conditioning evaporator thermal expansion valve and tighten to 22 (16 lb ft).
  5. Install NEW sealing washer (3) to the air conditioning compressor hose (2).
  6. Install the air conditioning compressor hose (2) to the air conditioning compressor.
  7. Install the air conditioning condenser hose. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  8. Install the air conditioning tube bracket bolt (1) to the generator and drive belt tensioner bracket and tighten to 22 (16 lb ft).
  9. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-651029-S17583717992014081900000) .
  10. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .
  1. Recover refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-651035-S07307479992014081900000) .
  3. Remove the air conditioning condenser hose from the compressor and position out of the way. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  4. Remove the air conditioning tube bracket bolt (1) from the generator and drive belt tensioner bracket.
  5. Remove the air conditioning compressor hose (2) from the air conditioning compressor.
  6. Remove and discard the old sealing washer (3) from the air conditioning compressor hose (2).
  7. Remove the air conditioning compressor hose nut (1) from the air conditioning evaporator thermal expansion valve.
  8. Remove the air conditioning compressor hose (2) from the air conditioning evaporator thermal expansion valve.
  9. Remove and discard the old sealing washer (3) from the air conditioning compressor hose (2).
  1. Install NEW sealing washer (3) to the air conditioning compressor hose (2). Refer to «Air Conditioning System Seal Replacement»(ref-651014-S07405085332014081900000) .
  2. Install the air conditioning compressor hose (2) to the vehicle.
  3. Install the air conditioning compressor hose (2) to the air conditioning evaporator thermal expansion valve.
  4. Install the air conditioning compressor hose nut (1) to the air conditioning evaporator thermal expansion valve and tighten to 22 (16 lb ft).
  5. Install NEW sealing washer (3) to the air conditioning compressor hose (2).
  6. Install the air conditioning compressor hose (2) to the air conditioning compressor.
  7. Install the air conditioning condenser hose. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  8. Install the air conditioning tube bracket bolt (1) to the generator and drive belt tensioner bracket and tighten to 22 (16 lb ft).
  9. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-651035-S07307479992014081900000) .
  10. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .

Scheme 1

Scheme 1: Air Conditioning Condenser Hose Replacement (LV3)
Scheme 1: Air Conditioning Condenser Hose Replacement (LV3)
CalloutComponent Name
Preliminary Procedure Recover refrigerant. Refer to Refrigerant Recovery and Recharging . Remove steering gear skid shield, if equipped. Refer to Steering Gear Skid Shield Replacement . Disconnect electrical connector from the air conditioning (A/C) refrigerant pressure sensor.
1Air Conditioning Condenser Hose Nut (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 22 (16 lb ft)
2Sealing Washer (Qty: 2) Procedure Remove and discard old sealing washers and replace with NEW sealing washers. Refer to Air Conditioning System Seal Replacement .
3Air Conditioning Condenser Hose Procedure If replacing the air conditioning compressor hose, transfer the air conditioning refrigerant pressure sensor. Refer to Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement .
CAUTION
Refer to Fastener Caution .

Air Conditioning Condenser Hose Replacement (LV3)

Air Conditioning Condenser Hose Replacement (L83)

CalloutComponent Name
Preliminary Procedure Recover refrigerant. Refer to Refrigerant Recovery and Recharging . Disconnect electrical connector from the air conditioning (A/C) refrigerant pressure sensor.
1Air Conditioning Condenser Hose Nut (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 22 (16 lb ft)
2Sealing Washer (Qty: 2) Procedure Remove and discard old sealing washers and replace with NEW sealing washers. Refer to Air Conditioning System Seal Replacement .
3Air Conditioning Condenser Hose Procedure If replacing the air conditioning compressor hose, transfer the air conditioning refrigerant pressure sensor. Refer to Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement .
CAUTION
Refer to Fastener Caution .

Air Conditioning Condenser Hose Replacement (L83)

  1. Recover refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-651029-S17583717992014081900000) .
  3. Remove the air conditioning compressor hose from the air conditioning evaporator thermal expansion valve and position out of the way. Refer to «Air Conditioning Compressor Hose Replacement (LV3)»(ref-651014-S28320602852014081900000) , «Air Conditioning Compressor Hose Replacement (L83)»(ref-651014-S18754430492014081900000) .
  4. Remove the air conditioning condenser hose from the air conditioning condenser and position out of the way. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  5. Remove the air conditioning evaporator tube (2) from the air conditioning condenser.
  6. Remove and discard the old sealing washer (1) from the air conditioning evaporator tube (2).
  7. Remove the air conditioning evaporator tube (2) from the air conditioning compressor and evaporator hose clip (1).
  8. Remove the air conditioning evaporator tube (2) from the air conditioning evaporator thermal expansion valve.
  9. Remove and discard the old sealing washer (3) from the air conditioning evaporator tube (2).
  1. Install NEW sealing washer (3) to the air conditioning evaporator tube (2). Refer to «Air Conditioning System Seal Replacement»(ref-651014-S07405085332014081900000) .
  2. Install the air conditioning evaporator tube (2) to the vehicle.
  3. Install the air conditioning evaporator tube (2) to the air conditioning evaporator thermal expansion valve.
  4. install the air conditioning evaporator tube (2) to the air conditioning compressor and evaporator hose clip (1).
  5. Install NEW sealing washer (1) to the air conditioning evaporator tube (2).
  6. Install the air conditioning evaporator tube (2) to the air conditioning condenser.
  7. Install the air conditioning condenser hose to the air conditioning condenser. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  8. Install the air conditioning compressor hose to the air conditioning evaporator thermal expansion valve. Refer to «Air Conditioning Compressor Hose Replacement (LV3)»(ref-651014-S28320602852014081900000) , «Air Conditioning Compressor Hose Replacement (L83)»(ref-651014-S18754430492014081900000) .
  9. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-651029-S17583717992014081900000) .
  10. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .
  1. Recover refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-651035-S07307479992014081900000) .
  3. Remove the air conditioning compressor hose from the air conditioning evaporator thermal expansion valve and position out of the way. Refer to «Air Conditioning Compressor Hose Replacement (LV3)»(ref-651014-S28320602852014081900000) , «Air Conditioning Compressor Hose Replacement (L83)»(ref-651014-S18754430492014081900000) .
  4. Remove the air conditioning condenser hose from the air conditioning condenser and position out of the way. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  5. Remove the air conditioning evaporator tube (2) from the air conditioning condenser.
  6. Remove and discard the old sealing washer (1) from the air conditioning evaporator tube (2).
  7. Remove the air conditioning evaporator tube (2) from the air conditioning compressor and evaporator hose clip (1).
  8. Remove the air conditioning evaporator tube (2) from the air conditioning evaporator thermal expansion valve.
  9. Remove and discard the old sealing washer (3) from the air conditioning evaporator tube (2).
  1. Install NEW sealing washer (3) to the air conditioning evaporator tube (2). Refer to «Air Conditioning System Seal Replacement»(ref-651014-S07405085332014081900000) .
  2. Install the air conditioning evaporator tube (2) to the vehicle.
  3. Install the air conditioning evaporator tube (2) to the air conditioning evaporator thermal expansion valve.
  4. install the air conditioning evaporator tube (2) to the air conditioning compressor and evaporator hose clip (1).
  5. Install NEW sealing washer (1) to the air conditioning evaporator tube (2).
  6. Install the air conditioning evaporator tube (2) to the air conditioning condenser.
  7. Install the air conditioning condenser hose to the air conditioning condenser. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  8. Install the air conditioning compressor hose to the air conditioning evaporator thermal expansion valve. Refer to «Air Conditioning Compressor Hose Replacement (LV3)»(ref-651014-S28320602852014081900000) , «Air Conditioning Compressor Hose Replacement (L83)»(ref-651014-S18754430492014081900000) .
  9. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-651035-S07307479992014081900000) .
  10. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .

Scheme 2

Scheme 2: Air Conditioning Refrigerant Service Valve Core Replacement
Scheme 2: Air Conditioning Refrigerant Service Valve Core Replacement
CalloutComponent Name
Preliminary Procedure Remove the service port cap. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
1Air Conditioning Refrigerant Service Valve CAUTION: Refer to Fastener Caution . Procedure Use GE-46246 tool to remove the air conditioning refrigerant valve. Replace the O-ring. Refer to Air Conditioning O-Ring Seal Replacement . Test the system for refrigerant leaks. Refer to Leak Testing . Tighten 2.5 N.m (22 lb in) Special Tools GE-46246 Valve Core Tool For equivalent region tools, refer to Special Tools .
CAUTION
Refer to Fastener Caution .

Air Conditioning Refrigerant Service Valve Core Replacement

Scheme 3

Scheme 3: Air Conditioning Compressor and Condenser Hose Fitting Replacement
Scheme 3: Air Conditioning Compressor and Condenser Hose Fitting Replacement
CalloutComponent Name
Preliminary Procedure Remove the service port cap. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
1Air Conditioning Refrigerant Service Valve CAUTION: Refer to Fastener Caution . Procedure Use GE-39037 socket to remove the air conditioning refrigerant valve. Replace the O-ring. Refer to Air Conditioning O-Ring Seal Replacement . Test the system for refrigerant leaks. Refer to Leak Testing . Tighten 2 N.m (18 lb in) Special Tools GE-39037 Charge Valve Octagon Socket For equivalent region tools, refer to Special Tools .
CAUTION
Refer to Fastener Caution .

Air Conditioning Compressor and Condenser Hose Fitting Replacement

Scheme 4

Scheme 4: Receiver and Dehydrator Replacement
Scheme 4: Receiver and Dehydrator Replacement
CalloutComponent Name
Preliminary Procedure Remove the air conditioning condenser. Refer to Air Conditioning Condenser Replacement (LV3) , Air Conditioning Condenser Replacement (L83) .
1Air Conditioning Refrigerant Desiccant CAUTION: Refer to Fastener Caution . NOTE: Cap all A/C components immediately to prevent system contamination.
CAUTION
Refer to Fastener Caution .
NOTE
Cap all A/C components immediately to prevent system contamination.

Receiver and Dehydrator Replacement

Scheme 5

Scheme 5: Air Conditioning Evaporator Thermal Expansion Valve Replacement
Scheme 5: Air Conditioning Evaporator Thermal Expansion Valve Replacement
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Disconnect the air conditioning evaporator tube from the air conditioning evaporator thermal expansion valve and position out of the way. Refer to Air Conditioning Evaporator Tube Replacement (LV3) , Air Conditioning Evaporator Tube Replacement (L83) .
1Air Conditioning Thermal Expansion Valve Bolt (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 7.5 (66 lb in)
2Air Conditioning Thermal Expansion Valve
3Air Conditioning Sealing Washer (Qty: 2) Procedure Remove and discard old sealing washers and replace with NEW sealing washers. Refer to Air Conditioning System Seal Replacement .
CAUTION
Refer to Fastener Caution .

Air Conditioning Evaporator Thermal Expansion Valve Replacement

Scheme 6

Scheme 6: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement
Scheme 6: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement
CalloutComponent Name
Preliminary Procedures Remove the steering gear skid shield, if equipped. Refer to Steering Gear Skid Shield Replacement . Disconnect the electrical connector from the air conditioning (A/C) refrigerant pressure sensor.
1A/C Refrigerant Pressure Sensor CAUTION: Refer to Fastener Caution . NOTE: Remove and discard the O-ring and replace with NEW only. Refer to Air Conditioning O-Ring Seal Replacement .
CAUTION
Refer to Fastener Caution .
NOTE
Remove and discard the O-ring and replace with NEW only. Refer to Air Conditioning O-Ring Seal Replacement .

Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement

Scheme 7

Scheme 7: Air Conditioning Condenser Replacement (LV3)
Scheme 7: Air Conditioning Condenser Replacement (LV3)
CalloutComponent Name
Preliminary Procedure Recover refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the radiator air upper baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (LV3 L83) . Remove the air conditioning condenser bracket. Refer to Air Conditioning Condenser Bracket Replacement (L83, LV3) . Remove the air conditioning evaporator tube from the condenser and position out of the way. Refer to Air Conditioning Evaporator Tube Replacement (LV3) , Air Conditioning Evaporator Tube Replacement (L83) .
1Air Conditioning Condenser Procedure Press in retaining tabs on the radiator and remove condenser from the vehicle. Remove the left radiator air baffle. Refer to Radiator Air Baffle Replacement - Left (LV3) , Radiator Air Baffle Replacement - Left (L83) . Remove the right radiator air baffle. Refer to Radiator Air Baffle Replacement - Right (LV3) , Radiator Air Baffle Replacement - Right (L83) . NOTE: If replacing the condenser, add refrigerant oil to the condenser. Refer to Refrigerant System Specifications for system capacity information.
NOTE
If replacing the condenser, add refrigerant oil to the condenser. Refer to Refrigerant System Specifications for system capacity information.

Air Conditioning Condenser Replacement (LV3)

Scheme 8

Scheme 8: Air Conditioning Condenser Replacement (L83)
Scheme 8: Air Conditioning Condenser Replacement (L83)
CalloutComponent Name
Preliminary Procedure Recover refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the radiator air upper baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (LV3 L83) . Remove the transmission fluid auxiliary cooler inlet pipe. Refer to Transmission Fluid Auxiliary Cooler Inlet Pipe Replacement (L83) . Remove the transmission fluid auxiliary cooler outlet pipe. Refer to Transmission Fluid Auxiliary Cooler Outlet Pipe Replacement (L83) . Remove the air conditioning condenser bracket. Refer to Air Conditioning Condenser Bracket Replacement (L83, LV3) . Remove the air conditioning evaporator tube from the condenser and position out of the way. Refer to Air Conditioning Evaporator Tube Replacement (LV3) , Air Conditioning Evaporator Tube Replacement (L83) .
1Air Conditioning Condenser Procedure Press in retaining tabs on the radiator and remove condenser from the vehicle. Remove the left radiator air baffle. Refer to Radiator Air Baffle Replacement - Left (LV3) , Radiator Air Baffle Replacement - Left (L83) . Remove the right radiator air baffle. Refer to Radiator Air Baffle Replacement - Right (LV3) , Radiator Air Baffle Replacement - Right (L83) . NOTE: If replacing the condenser, add refrigerant oil to the condenser. Refer to Refrigerant System Specifications for system capacity information.
NOTE
If replacing the condenser, add refrigerant oil to the condenser. Refer to Refrigerant System Specifications for system capacity information.

Air Conditioning Condenser Replacement (L83)

  1. Remove the radiator air upper baffle and deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement (LV3 L83)»(ref-651030-S02292542272014081900000) .
  2. Remove the air conditioning condenser bolt (1) from the radiator.
  3. Remove the air conditioning condenser bracket (2) from the vehicle.
  1. Install the air conditioning condenser bracket (2) to the air conditioning condenser.
  2. Tighten 6 (53 lb in)
  3. Install the air conditioning condenser bolt (1) to the radiator.
  4. Install the radiator air upper baffle and deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement (LV3 L83)»(ref-651030-S02292542272014081900000) .
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (L83, L86, LV1, LV3)»(ref-651026-S08403881682014081900000) , «Battery Negative Cable Disconnection and Connection (K4B)»(ref-651026-S42555838012014081900000) .
  2. Drain the engine coolant system. Refer to «Cooling System Draining and Filling (Vac-N-Fill Gasoline)»(ref-651030-S17228941602014081900000) , «Cooling System Draining and Filling (Static Fill)»(ref-651030-S35285794042014081900000) .
  3. Remove the battery tray. Refer to «Battery Tray Replacement»(ref-651026-S34340649122014081900000) .
  4. Remove the heater inlet hose from the heater core tube. Refer to «Heater Inlet Hose Replacement (L83)»(ref-651014-S20806797292014081900000) , «Heater Inlet Hose Replacement (LV3)»(ref-651014-S34934646452014081900000) .
  5. Remove the heater outlet hose from the heater core tube. Refer to «Heater Outlet Hose Replacement (L83)»(ref-651014-S11519185592014081900000) , «Heater Outlet Hose Replacement (LV3)»(ref-651014-S23643568472014081900000) .
  6. Remove the fuel pump Insulator. Refer to «Fuel Pump Insulator Replacement»(ref-651035-S11586102892014081900000) .
  7. Remove the right side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Right Side»(ref-651014-S15953390102014081900000) .
  8. Remove the left side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Left Side»(ref-651014-S04566736502014081900000) .
  9. Remove the instrument panel tie bar assembly. Refer to «Instrument Panel Tie Bar Replacement»(ref-651009-S01078682632014081900000) .
  10. Temporary support the heater and blower module assembly (HVAC).
  11. From within the engine compartment, remove the air conditioning evaporator case drain tube (1) from the HVAC module assembly.
  12. Remove the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  13. Remove the HVAC module assembly bolts, (3) securing the HVAC module assembly to the cowl panel.
  14. Remove the HVAC module assembly bolts, (1) securing the HVAC module assembly to the cowl panel.
  15. Remove the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  16. Remove the HVAC module assembly (1) from the vehicle.
  17. Transfer all the necessary components.
  1. Position the HVAC module assembly (1) into the vehicle and temporarily support it.
  2. From within the engine compartment, install the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel and tighten to 9.5 (84 lb in).
  3. Install the HVAC module assembly bolts, (1) securing the HVAC module assembly to the cowl panel.
  4. Install the HVAC module assembly bolts, (3) securing the HVAC module assembly to the cowl panel.
  5. Install the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  6. Install the air conditioning evaporator case drain tube (1) onto the HVAC module assembly.
  7. Install the instrument panel tie bar assembly. Refer to «Instrument Panel Tie Bar Replacement»(ref-651009-S01078682632014081900000) .
  8. Install the left side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Left Side»(ref-651014-S04566736502014081900000) .
  9. Install the right side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Right Side»(ref-651014-S15953390102014081900000) .
  10. Install the fuel pump Insulator. Refer to «Fuel Pump Insulator Replacement»(ref-651035-S11586102892014081900000) .
  11. Install the heater outlet hose to the heater core tube. Refer to «Heater Outlet Hose Replacement (L83)»(ref-651014-S11519185592014081900000) , «Heater Outlet Hose Replacement (LV3)»(ref-651014-S23643568472014081900000) .
  12. Install the heater inlet hose to the heater core tube. Refer to «Heater Inlet Hose Replacement (L83)»(ref-651014-S20806797292014081900000) , «Heater Inlet Hose Replacement (LV3)»(ref-651014-S34934646452014081900000) .
  13. Install the battery tray. Refer to «Battery Tray Replacement»(ref-651026-S34340649122014081900000) .
  14. Fill the engine coolant system. Refer to «Cooling System Draining and Filling (Vac-N-Fill Gasoline)»(ref-651030-S17228941602014081900000) , «Cooling System Draining and Filling (Static Fill)»(ref-651030-S35285794042014081900000) .
  15. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (L83, L86, LV1, LV3)»(ref-651026-S08403881682014081900000) , «Battery Negative Cable Disconnection and Connection (K4B)»(ref-651026-S42555838012014081900000) .
  16. Visually inspect for coolant leaks.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (L83, L86, LV1, LV3)»(ref-651026-S08403881682014081900000) , «Battery Negative Cable Disconnection and Connection (K4B)»(ref-651026-S42555838012014081900000) .
  2. Drain the engine coolant system. Refer to «Cooling System Draining and Filling (Vac-N-Fill Gasoline)»(ref-651030-S17228941602014081900000) , «Cooling System Draining and Filling (Static Fill)»(ref-651030-S35285794042014081900000) .
  3. Remove the battery tray. Refer to «Battery Tray Replacement»(ref-651026-S34340649122014081900000) .
  4. Remove the heater inlet hose from the heater core tube. Refer to «Heater Inlet Hose Replacement (L83)»(ref-651014-S20806797292014081900000) , «Heater Inlet Hose Replacement (LV3)»(ref-651014-S34934646452014081900000) .
  5. Remove the heater outlet hose from the heater core tube. Refer to «Heater Outlet Hose Replacement (L83)»(ref-651014-S11519185592014081900000) , «Heater Outlet Hose Replacement (LV3)»(ref-651014-S23643568472014081900000) .
  6. Remove the fuel pump Insulator. Refer to «Fuel Pump Insulator Replacement»(ref-651029-S21615622332014081900000) .
  7. Remove the right side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Right Side»(ref-651014-S15953390102014081900000) .
  8. Remove the left side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Left Side»(ref-651014-S04566736502014081900000) .
  9. Remove the instrument panel tie bar assembly. Refer to «Instrument Panel Tie Bar Replacement»(ref-651009-S01078682632014081900000) .
  10. Temporary support the heater and blower module assembly (HVAC).
  11. From within the engine compartment, remove the air conditioning evaporator case drain tube (1) from the HVAC module assembly.
  12. Remove the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  13. Remove the HVAC module assembly bolts, (3) securing the HVAC module assembly to the cowl panel.
  14. Remove the HVAC module assembly bolts, (1) securing the HVAC module assembly to the cowl panel.
  15. Remove the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  16. Remove the HVAC module assembly (1) from the vehicle.
  17. Transfer all the necessary components.
  1. Position the HVAC module assembly (1) into the vehicle and temporarily support it.
  2. From within the engine compartment, install the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel and tighten to 9.5 (84 lb in).
  3. Install the HVAC module assembly bolts, (1) securing the HVAC module assembly to the cowl panel.
  4. Install the HVAC module assembly bolts, (3) securing the HVAC module assembly to the cowl panel.
  5. Install the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  6. Install the air conditioning evaporator case drain tube (1) onto the HVAC module assembly.
  7. Install the instrument panel tie bar assembly. Refer to «Instrument Panel Tie Bar Replacement»(ref-651009-S01078682632014081900000) .
  8. Install the left side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Left Side»(ref-651014-S04566736502014081900000) .
  9. Install the right side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Right Side»(ref-651014-S15953390102014081900000) .
  10. Install the fuel pump Insulator. Refer to «Fuel Pump Insulator Replacement»(ref-651029-S21615622332014081900000) .
  11. Install the heater outlet hose to the heater core tube. Refer to «Heater Outlet Hose Replacement (L83)»(ref-651014-S11519185592014081900000) , «Heater Outlet Hose Replacement (LV3)»(ref-651014-S23643568472014081900000) .
  12. Install the heater inlet hose to the heater core tube. Refer to «Heater Inlet Hose Replacement (L83)»(ref-651014-S20806797292014081900000) , «Heater Inlet Hose Replacement (LV3)»(ref-651014-S34934646452014081900000) .
  13. Install the battery tray. Refer to «Battery Tray Replacement»(ref-651026-S34340649122014081900000) .
  14. Fill the engine coolant system. Refer to «Cooling System Draining and Filling (Vac-N-Fill Gasoline)»(ref-651030-S17228941602014081900000) , «Cooling System Draining and Filling (Static Fill)»(ref-651030-S35285794042014081900000) .
  15. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (L83, L86, LV1, LV3)»(ref-651026-S08403881682014081900000) , «Battery Negative Cable Disconnection and Connection (K4B)»(ref-651026-S42555838012014081900000) .
  16. Visually inspect for coolant leaks.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (L83, L86, LV1, LV3)»(ref-651026-S08403881682014081900000) , «Battery Negative Cable Disconnection and Connection (K4B)»(ref-651026-S42555838012014081900000) .
  2. Recover the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .
  3. Drain the engine coolant system. Refer to «Cooling System Draining and Filling (Vac-N-Fill Gasoline)»(ref-651030-S17228941602014081900000) , «Cooling System Draining and Filling (Static Fill)»(ref-651030-S35285794042014081900000) .
  4. Remove the battery tray. Refer to «Battery Tray Replacement»(ref-651026-S34340649122014081900000) .
  5. Remove the heater inlet hose from the heater core tube. Refer to «Heater Inlet Hose Replacement (L83)»(ref-651014-S20806797292014081900000) , «Heater Inlet Hose Replacement (LV3)»(ref-651014-S34934646452014081900000) .
  6. Remove the heater outlet hose from the heater core tube. Refer to «Heater Outlet Hose Replacement (L83)»(ref-651014-S11519185592014081900000) , «Heater Outlet Hose Replacement (LV3)»(ref-651014-S23643568472014081900000) .
  7. Remove the air conditioning evaporator tube from the thermal expansion valve. Refer to «Air Conditioning Evaporator Tube Replacement (LV3)»(ref-651014-S34385291122014081900000) , «Air Conditioning Evaporator Tube Replacement (L83)»(ref-651014-S03587216552014081900000) .
  8. Remove the air conditioning condenser hose from the thermal expansion valve. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  9. Remove the fuel pump Insulator. Refer to «Fuel Pump Insulator Replacement»(ref-651035-S11586102892014081900000) .
  10. Remove the right side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Right Side»(ref-651014-S15953390102014081900000) .
  11. Remove the left side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Left Side»(ref-651014-S04566736502014081900000) .
  12. Remove the instrument panel tie bar assembly. Refer to «Instrument Panel Tie Bar Replacement»(ref-651009-S01078682632014081900000) .
  13. Temporary support the heater and air conditioning evaporator and blower module assembly.
  14. From within the engine compartment, remove the air conditioning evaporator case drain tube (1) from the HVAC module assembly.
  15. Remove the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  16. Remove the HVAC module assembly bolts, (3) securing the HVAC module assembly to the cowl panel.
  17. Remove the HVAC module assembly bolts, (1) securing the HVAC module assembly to the cowl panel.
  18. Remove the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  19. Remove the HVAC module assembly (1) from the vehicle.
  20. Transfer all the necessary components.
  1. Position the HVAC module assembly (1) into the vehicle and temporarily support it.
  2. From within the engine compartment, install the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel and tighten to 9.5 (84 lb in).
  3. Install the HVAC module assembly bolts, (1) securing the HVAC module assembly to the cowl panel.
  4. Install the HVAC module assembly bolts, (3) securing the HVAC module assembly to the cowl panel.
  5. Install the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  6. Install the air conditioning evaporator case drain tube (1) onto the HVAC module assembly.
  7. Install the instrument panel tie bar assembly. Refer to «Instrument Panel Tie Bar Replacement»(ref-651009-S01078682632014081900000) .
  8. Install the left side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Left Side»(ref-651014-S04566736502014081900000) .
  9. Install the right side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Right Side»(ref-651014-S15953390102014081900000) .
  10. Install the fuel pump Insulator. Refer to «Fuel Pump Insulator Replacement»(ref-651035-S11586102892014081900000) .
  11. Install the air conditioning condenser hose to the thermal expansion valve. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  12. Install the air conditioning evaporator tube to the thermal expansion valve. Refer to «Air Conditioning Evaporator Tube Replacement (LV3)»(ref-651014-S34385291122014081900000) , «Air Conditioning Evaporator Tube Replacement (L83)»(ref-651014-S03587216552014081900000) .
  13. Install the heater outlet hose to the heater core tube. Refer to «Heater Outlet Hose Replacement (L83)»(ref-651014-S11519185592014081900000) , «Heater Outlet Hose Replacement (LV3)»(ref-651014-S23643568472014081900000) .
  14. Install the heater inlet hose to the heater core tube. Refer to «Heater Inlet Hose Replacement (L83)»(ref-651014-S20806797292014081900000) , «Heater Inlet Hose Replacement (LV3)»(ref-651014-S34934646452014081900000) .
  15. Install the battery tray. Refer to «Battery Tray Replacement»(ref-651026-S34340649122014081900000) .
  16. Fill the engine coolant system. Refer to «Cooling System Draining and Filling (Vac-N-Fill Gasoline)»(ref-651030-S17228941602014081900000) , «Cooling System Draining and Filling (Static Fill)»(ref-651030-S35285794042014081900000) .
  17. Recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .
  18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (L83, L86, LV1, LV3)»(ref-651026-S08403881682014081900000) , «Battery Negative Cable Disconnection and Connection (K4B)»(ref-651026-S42555838012014081900000) .
  19. Visually inspect for coolant leaks.
  20. Visually inspect for refrigerant leaks.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (L83, L86, LV1, LV3)»(ref-651026-S08403881682014081900000) , «Battery Negative Cable Disconnection and Connection (K4B)»(ref-651026-S42555838012014081900000) .
  2. Recover the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .
  3. Drain the engine coolant system. Refer to «Cooling System Draining and Filling (Vac-N-Fill Gasoline)»(ref-651030-S17228941602014081900000) , «Cooling System Draining and Filling (Static Fill)»(ref-651030-S35285794042014081900000) .
  4. Remove the battery tray. Refer to «Battery Tray Replacement»(ref-651026-S34340649122014081900000) .
  5. Remove the heater inlet hose from the heater core tube. Refer to «Heater Inlet Hose Replacement (L83)»(ref-651014-S20806797292014081900000) , «Heater Inlet Hose Replacement (LV3)»(ref-651014-S34934646452014081900000) .
  6. Remove the heater outlet hose from the heater core tube. Refer to «Heater Outlet Hose Replacement (L83)»(ref-651014-S11519185592014081900000) , «Heater Outlet Hose Replacement (LV3)»(ref-651014-S23643568472014081900000) .
  7. Remove the air conditioning evaporator tube from the thermal expansion valve. Refer to «Air Conditioning Evaporator Tube Replacement (LV3)»(ref-651014-S34385291122014081900000) , «Air Conditioning Evaporator Tube Replacement (L83)»(ref-651014-S03587216552014081900000) .
  8. Remove the air conditioning condenser hose from the thermal expansion valve. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  9. Remove the fuel pump Insulator. Refer to «Fuel Pump Insulator Replacement»(ref-651029-S21615622332014081900000) .
  10. Remove the right side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Right Side»(ref-651014-S15953390102014081900000) .
  11. Remove the left side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Left Side»(ref-651014-S04566736502014081900000) .
  12. Remove the instrument panel tie bar assembly. Refer to «Instrument Panel Tie Bar Replacement»(ref-651009-S01078682632014081900000) .
  13. Temporary support the heater and air conditioning evaporator and blower module assembly.
  14. From within the engine compartment, remove the air conditioning evaporator case drain tube (1) from the HVAC module assembly.
  15. Remove the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  16. Remove the HVAC module assembly bolts, (3) securing the HVAC module assembly to the cowl panel.
  17. Remove the HVAC module assembly bolts, (1) securing the HVAC module assembly to the cowl panel.
  18. Remove the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  19. Remove the HVAC module assembly (1) from the vehicle.
  20. Transfer all the necessary components.
  1. Position the HVAC module assembly (1) into the vehicle and temporarily support it.
  2. From within the engine compartment, install the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel and tighten to 9.5 (84 lb in).
  3. Install the HVAC module assembly bolts, (1) securing the HVAC module assembly to the cowl panel.
  4. Install the HVAC module assembly bolts, (3) securing the HVAC module assembly to the cowl panel.
  5. Install the HVAC module assembly nut, (2) securing the HVAC module assembly to the cowl panel.
  6. Install the air conditioning evaporator case drain tube (1) onto the HVAC module assembly.
  7. Install the instrument panel tie bar assembly. Refer to «Instrument Panel Tie Bar Replacement»(ref-651009-S01078682632014081900000) .
  8. Install the left side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Left Side»(ref-651014-S04566736502014081900000) .
  9. Install the right side floor rear air outlet duct. Refer to «Floor Front Air Outlet Duct Replacement - Right Side»(ref-651014-S15953390102014081900000) .
  10. Install the fuel pump Insulator. Refer to «Fuel Pump Insulator Replacement»(ref-651029-S21615622332014081900000) .
  11. Install the air conditioning condenser hose to the thermal expansion valve. Refer to «Air Conditioning Condenser Hose Replacement (LV3)»(ref-651014-S18418444642014081900000) , «Air Conditioning Condenser Hose Replacement (L83)»(ref-651014-S00849297842014081900000) .
  12. Install the air conditioning evaporator tube to the thermal expansion valve. Refer to «Air Conditioning Evaporator Tube Replacement (LV3)»(ref-651014-S34385291122014081900000) , «Air Conditioning Evaporator Tube Replacement (L83)»(ref-651014-S03587216552014081900000) .
  13. Install the heater outlet hose to the heater core tube. Refer to «Heater Outlet Hose Replacement (L83)»(ref-651014-S11519185592014081900000) , «Heater Outlet Hose Replacement (LV3)»(ref-651014-S23643568472014081900000) .
  14. Install the heater inlet hose to the heater core tube. Refer to «Heater Inlet Hose Replacement (L83)»(ref-651014-S20806797292014081900000) , «Heater Inlet Hose Replacement (LV3)»(ref-651014-S34934646452014081900000) .
  15. Install the battery tray. Refer to «Battery Tray Replacement»(ref-651026-S34340649122014081900000) .
  16. Fill the engine coolant system. Refer to «Cooling System Draining and Filling (Vac-N-Fill Gasoline)»(ref-651030-S17228941602014081900000) , «Cooling System Draining and Filling (Static Fill)»(ref-651030-S35285794042014081900000) .
  17. Recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-651014-S06911667582014081900000) .
  18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (L83, L86, LV1, LV3)»(ref-651026-S08403881682014081900000) , «Battery Negative Cable Disconnection and Connection (K4B)»(ref-651026-S42555838012014081900000) .
  19. Visually inspect for coolant leaks.
  20. Visually inspect for refrigerant leaks.

Scheme 9

Scheme 9: Heater and Air Conditioning Evaporator Case Replacement (C42)
Scheme 9: Heater and Air Conditioning Evaporator Case Replacement (C42)
CalloutComponent Name
Preliminary Procedures Remove the heater and blower module assembly. Refer to Heater and Blower Module Removal and Installation (With C42, L83, MCX) , Heater and Blower Module Removal and Installation (WITH C42, LV1, LV3, MCX) . Disconnect the electrical connectors as necessary.
1Air Inlet Housing Assembly Refer to Air Inlet Housing Replacement .
2Air Distributor Case Assembly Refer to Air Distributor Case Replacement .
3Heater and Air Conditioning Evaporator Case Assembly Procedures Remove the heater core assembly. Refer to Heater Core Replacement . Remove the blower motor assembly. Refer to Blower Assembly Replacement . Remove the temperature valve actuator. Refer to Temperature Valve Actuator Replacement . Transfer the components as necessary.

Heater and Air Conditioning Evaporator Case Replacement (C42)

Heater and Air Conditioning Evaporator Case Replacement (C67, CJ2)

CalloutComponent Name
Preliminary Procedures Remove the heater and air conditioning evaporator and blower module assembly. Refer to Heater and Air Conditioning Evaporator and Blower Module Removal and Installation (With L83, L86) , Heater and Air Conditioning Evaporator and Blower Module Removal and Installation (With LV1 LV3) . Disconnect the electrical connectors as necessary.
1Air Inlet Housing Assembly Refer to Air Inlet Housing Replacement .
2Air Distributor Case Assembly Refer to Air Distributor Case Replacement .
3Heater and Air Conditioning Evaporator Case Assembly Procedures Remove the heater core assembly. Refer to Heater Core Replacement . Remove the air conditioning evaporator core assembly. Refer to Air Conditioning Evaporator Core Replacement . Remove the blower motor assembly. Refer to Blower Assembly Replacement . Remove the left side temperature valve actuator if equipped. Refer to Temperature Valve Actuator Replacement - Left Side (CJ2) . Remove the right side temperature valve actuator. Refer to Temperature Valve Actuator Replacement . Transfer the components as necessary.

Heater and Air Conditioning Evaporator Case Replacement (C67, CJ2)

Scheme 10

Scheme 10: Blower Assembly Replacement
Scheme 10: Blower Assembly Replacement
CalloutComponent Name
Preliminary Procedure Remove the right side instrument panel insulator. Refer to Instrument Panel Insulator Replacement (RPO D07) , Instrument Panel Insulator Replacement (Without RPO D07) .
1Blower Motor Fastener (Qty: 3) CAUTION: Refer to Fastener Caution .
2Blower Motor Assembly Procedure Disconnect the blower motor assembly electrical connector.
CAUTION
Refer to Fastener Caution .

Blower Assembly Replacement

Scheme 11

Scheme 11: Air Conditioning Evaporator Core Replacement
Scheme 11: Air Conditioning Evaporator Core Replacement
CalloutComponent Name
Preliminary Procedures Remove the heater and air conditioning evaporator and blower module assembly. Refer to Heater and Air Conditioning Evaporator and Blower Module Removal and Installation (With L83, L86) , Heater and Air Conditioning Evaporator and Blower Module Removal and Installation (With LV1 LV3) . Remove the temperature valve actuator. Refer to Temperature Valve Actuator Replacement . Disconnect the electrical connectors as necessary.
1Seal (Qty: 2)
2Heater Cover Fastener (Qty: 12) CAUTION: Refer to Fastener Caution .
3Heater Cover
4Air Conditioning Evaporator Core Procedures Lift the air conditioning evaporator core up and out of the heater and air conditioning evaporator and blower module assembly. Transfer the components as necessary.
CAUTION
Refer to Fastener Caution .

Air Conditioning Evaporator Core Replacement

Scheme 12

Scheme 12: Air Conditioning Evaporator and Blower Module Drain Lower Hose Replacement
Scheme 12: Air Conditioning Evaporator and Blower Module Drain Lower Hose Replacement
CalloutComponent Name
1Air Conditioning Evaporator and Blower Module Drain Lower Hose

Air Conditioning Evaporator and Blower Module Drain Lower Hose Replacement

Scheme 13

Scheme 13: Heater Inlet Hose Replacement (L83)
Scheme 13: Heater Inlet Hose Replacement (L83)
CalloutComponent Name
Preliminary Procedures Drain the coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill Gasoline) , Cooling System Draining and Filling (Static Fill) . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
1Heater Inlet Hose Clamp Procedure Reposition the heater inlet hose clamp using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools .
2Heater Inlet Hose Quick Disconnect Special Tools J-43181 Heater Line Q.C. Release Tool For equivalent regional tools, Refer to Special Tools .
3Heater Inlet Hose Procedure Remove heater inlet hose from retainer.

Heater Inlet Hose Replacement (L83)

Heater Inlet Hose Replacement (LV3)

CalloutComponent Name
Preliminary Procedures Drain the coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill Gasoline) , Cooling System Draining and Filling (Static Fill) . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
1Heater Inlet Hose Clamp Procedure Reposition the heater inlet hose clamp using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools .
2Heater Inlet Hose Quick Disconnect Special Tools J-43181 Heater Line Q.C. Release Tool For equivalent regional tools, Refer to Special Tools .
3Heater Inlet Hose Procedure Remove heater inlet hose from retainer.

Heater Inlet Hose Replacement (LV3)

Scheme 14

Scheme 14: Heater Outlet Hose Replacement (L83)
Scheme 14: Heater Outlet Hose Replacement (L83)
CalloutComponent Name
Preliminary Procedures Drain the coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill Gasoline) , Cooling System Draining and Filling (Static Fill) . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
1Heater Outlet Hose Clamp Procedure Reposition the heater outlet hose clamp using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools .
2Heater Outlet Hose Quick Disconnect Special Tools J-43181 Heater Line Q.C. Release Tool For equivalent regional tools, Refer to Special Tools .
3Heater Outlet Hose Procedures Remove heater outlet hose from retainer. Fill the cooling system to the proper level. Inspect the cooing system for leaks.

Heater Outlet Hose Replacement (L83)

Heater Outlet Hose Replacement (LV3)

CalloutComponent Name
Preliminary Procedures Drain the coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill Gasoline) , Cooling System Draining and Filling (Static Fill) . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
1Heater Outlet Hose Clamp Procedure Reposition the heater outlet hose clamp using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools .
2Heater Outlet Hose Quick Disconnect Special Tools J-43181 Heater Line Q.C. Release Tool For equivalent regional tools, Refer to Special Tools .
3Heater Outlet Hose Procedures Remove heater outlet hose from retainer. Fill the cooling system to the proper level. Inspect the cooing system for leaks.

Heater Outlet Hose Replacement (LV3)

Scheme 15

Scheme 15: Passenger Compartment Air Filter Replacement
Scheme 15: Passenger Compartment Air Filter Replacement
CalloutComponent Name
Preliminary Procedure Remove the Instrument Panel Compartment assembly. Refer to Instrument Panel Compartment Replacement .
1Passenger Compartment Air Inlet Filter Cover
2Passenger Compartment Air Filter

Passenger Compartment Air Filter Replacement

Scheme 16

Scheme 16: Air Inlet Housing Replacement
Scheme 16: Air Inlet Housing Replacement
CalloutComponent Name
Preliminary Procedures Remove the heater and air conditioning evaporator and blower module assembly. Refer to Heater and Air Conditioning Evaporator and Blower Module Removal and Installation (With L83, L86) , Heater and Air Conditioning Evaporator and Blower Module Removal and Installation (With LV1 LV3) . Disconnect the electrical connectors as necessary.
1Air Inlet Housing Fastener (Qty: 2) CAUTION: Refer to Fastener Caution .
2Air Inlet Housing Assembly Procedure Transfer the components as necessary.
CAUTION
Refer to Fastener Caution .

Air Inlet Housing Replacement

Scheme 17

Scheme 17: Air Distributor Case Replacement
Scheme 17: Air Distributor Case Replacement
CalloutComponent Name
Preliminary Procedures Remove the instrument panel tie bar assembly. Refer to Instrument Panel Tie Bar Replacement . Remove the mode control cam assembly. Refer to Mode Control Cam Replacement (CJ2)
1Air Distributor Case Fastener (Qty: 5) CAUTION: Refer to Fastener Caution .
2Air Distributor Case Procedure Transfer the components as necessary.
CAUTION
Refer to Fastener Caution .

Air Distributor Case Replacement

Scheme 18

Scheme 18: Instrument Panel Outer Air Outlet Replacement - Left Side
Scheme 18: Instrument Panel Outer Air Outlet Replacement - Left Side
CalloutComponent Name
Preliminary Procedure Remove the left instrument panel trim plate. Refer to Instrument Panel Trim Plate Replacement - Left Side .
1Instrument Panel Air Outlet Duct Bolt (Qty: 3) CAUTION: Refer to Fastener Caution . Tighten 2.5 (22 lb in)
2Instrument Panel Outer Air Outlet - Left Side
CAUTION
Refer to Fastener Caution .

Instrument Panel Outer Air Outlet Replacement - Left Side

Scheme 19

Scheme 19: Instrument Panel Center Air Outlet Replacement
Scheme 19: Instrument Panel Center Air Outlet Replacement
CalloutComponent Name
Preliminary Procedure Remove the radio control assembly. Refer to Radio Control Assembly Replacement .
1Instrument Panel Air Outlet Duct Bolt (Qty: 6) CAUTION: Refer to Fastener Caution . Tighten 2.5 (22 lb in)
2Instrument Panel Center Air Outlet - Left Side
3Instrument Panel Center Air Outlet - Right Side
CAUTION
Refer to Fastener Caution .

Instrument Panel Center Air Outlet Replacement

Scheme 20

Scheme 20: Instrument Panel Outer Air Outlet Replacement - Right Side
Scheme 20: Instrument Panel Outer Air Outlet Replacement - Right Side
CalloutComponent Name
Preliminary Procedure Remove the right instrument panel trim plate. Refer to Instrument Panel Trim Plate Replacement - Right Side .
1Instrument Panel Air Outlet Duct Bolt (Qty: 3) CAUTION: Refer to Fastener Caution . Tighten 2.5 (22 lb in)
2Instrument Panel Outer Air Outlet - Right Side
CAUTION
Refer to Fastener Caution .

Instrument Panel Outer Air Outlet Replacement - Right Side

Scheme 21

Scheme 21: Floor Front Air Outlet Duct Replacement - Right Side
Scheme 21: Floor Front Air Outlet Duct Replacement - Right Side
CalloutComponent Name
Preliminary Procedure Remove the right side instrument panel insulator. Refer to Instrument Panel Insulator Replacement (RPO D07) , Instrument Panel Insulator Replacement (Without RPO D07) .
1Floor Front Air Outlet Duct Fastener CAUTION: Refer to Fastener Caution .
2Floor Front Air Outlet Duct - Right Side
CAUTION
Refer to Fastener Caution .

Floor Front Air Outlet Duct Replacement - Right Side

Scheme 22

Scheme 22: Floor Front Air Outlet Duct Replacement - Left Side
Scheme 22: Floor Front Air Outlet Duct Replacement - Left Side
CalloutComponent Name
Preliminary Procedure Remove the instrument panel knee bolster. Refer to Instrument Panel Knee Bolster Replacement .
1Floor Front Air Outlet Duct Fastener
2Floor Front Air Outlet Duct - Right Side

Floor Front Air Outlet Duct Replacement - Left Side

Scheme 23

Scheme 23: Floor Air Outlet Duct Replacement - Center
Scheme 23: Floor Air Outlet Duct Replacement - Center
CalloutComponent Name
Preliminary Procedures Remove the left front floor air outlet duct. Refer to Floor Front Air Outlet Duct Replacement - Left Side . Remove the right front floor air outlet duct. Refer to Floor Front Air Outlet Duct Replacement - Right Side . Remove the floor rear air outlet duct. Refer to Floor Rear Air Outlet Duct Replacement .
1Center Floor Duct Fastener (Qty: 3) CAUTION: Refer to Fastener Caution .
2Center Floor Duct Procedure Maneuver the center floor duct out from under the dash from the left side.
CAUTION
Refer to Fastener Caution .

Floor Air Outlet Duct Replacement - Center

Scheme 24

Scheme 24: Air Distributor Front Duct Replacement
Scheme 24: Air Distributor Front Duct Replacement
CalloutComponent Name
Preliminary Procedures Remove the instrument panel assembly. Refer to Instrument Panel Assembly Removal . Remove the left side window defogger outlet duct. Refer to Side Window Defogger Outlet Duct Replacement - Left Side . Remove the right side window defogger outlet duct. Refer to Side Window Defogger Outlet Duct Replacement - Right Side .
1Air Distributor Front Duct Fastener (Qty: 8) CAUTION: Refer to Fastener Caution .
2Air Distributor Front Duct
CAUTION
Refer to Fastener Caution .

Air Distributor Front Duct Replacement

Scheme 25

Scheme 25: Side Window Defogger Outlet Duct Replacement - Left Side
Scheme 25: Side Window Defogger Outlet Duct Replacement - Left Side
CalloutComponent Name
Preliminary Procedure Remove the instrument panel assembly. Refer to Instrument Panel Assembly Removal .
1Side Window Defogger Outlet Duct Fastener (Qty: 2) CAUTION: Refer to Fastener Caution .
2Side Window Defogger Outlet Duct - Left Side Procedure Remove the wiring harness from the right side window defogger outlet duct.
CAUTION
Refer to Fastener Caution .

Side Window Defogger Outlet Duct Replacement - Left Side

Scheme 26

Scheme 26: Side Window Defogger Outlet Duct Replacement - Right Side
Scheme 26: Side Window Defogger Outlet Duct Replacement - Right Side
CalloutComponent Name
Preliminary Procedure Remove the instrument panel assembly. Refer to Instrument Panel Assembly Removal .
1Side Window Defogger Outlet Duct Fastener (Qty: 2) CAUTION: Refer to Fastener Caution .
2Side Window Defogger Outlet Duct - Right Side Procedure Remove the wiring harness from the right side window defogger outlet duct.
CAUTION
Refer to Fastener Caution .

Side Window Defogger Outlet Duct Replacement - Right Side

Scheme 27

Scheme 27: Floor Rear Air Outlet Duct Replacement
Scheme 27: Floor Rear Air Outlet Duct Replacement
CalloutComponent Name
Preliminary Procedure Remove the floor panel carpet. Refer to Floor Panel Carpet Replacement (Crew Cab) , Floor Panel Carpet Replacement (Extended Cab) .
1Floor Rear Air Outlet Duct - Front Procedure Removing the floor rear air outlet duct as an assembly, separate the ducts.
2Floor Rear Air Outlet Duct - intermediate Procedure Removing the floor rear air outlet duct as an assembly, separate the ducts.
3Floor Rear Air Outlet Duct - Rear

Floor Rear Air Outlet Duct Replacement

Scheme 28

Scheme 28: Heater and Air Conditioning Control Cam Replacement (Air Inlet)
Scheme 28: Heater and Air Conditioning Control Cam Replacement (Air Inlet)
CalloutComponent Name
Preliminary Procedure Remove the air inlet valve actuator. Refer to Air Inlet Valve Actuator Replacement .
1Air Inlet Valve Link
2Air Inlet Valve Lever

Heater and Air Conditioning Control Cam Replacement (Air Inlet)

Scheme 29

Scheme 29: Heater Core Replacement
Scheme 29: Heater Core Replacement
CalloutComponent Name
Preliminary Procedures Remove the heater and air conditioning evaporator and blower module assembly. Refer to Heater and Air Conditioning Evaporator and Blower Module Removal and Installation (With L83, L86) , Heater and Air Conditioning Evaporator and Blower Module Removal and Installation (With LV1 LV3) . Remove the temperature valve actuator. Refer to Temperature Valve Actuator Replacement . Disconnect the electrical connectors as necessary.
1Seal (Qty: 2)
2Heater Cover Fastener (Qty: 12) CAUTION: Refer to Fastener Caution .
3Heater Cover
4Heater Core Assembly Procedures Lift the heater core up and out of the heater and air conditioning evaporator and blower module assembly. Transfer the components as necessary.
CAUTION
Refer to Fastener Caution .

Heater Core Replacement

More articles — Heating, Ventilation, and Air Conditioning