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Heating, Ventilation & Air Conditioning: Removal & Installation GMC Yukon Denali

Automatic HVAC System ~7529 words

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Remove the serpentine drive belt.
  3. Raise and support the vehicle.
  4. Remove the right front tire and wheel assembly.
  5. Remove the inner fender skirt.
  6. Remove the compressor/condenser hose. Refer to «Compressor Hose Assembly Replacement (L35 w/ Harrison)»(ref-235300-S00957335692006061900000) or «Compressor Hose Assembly Replacement (LR4, LM7, LQ4 w/ Harrison)»(ref-235300-S22526607072006061900000) .
  7. Remove the discharge hose. Refer to «Discharge Hose Replacement (LR4, LM7, LQ4 w/ Denso)»(ref-235300-S22317495672006061900000) .
  8. Remove the suction hose. Refer to «Suction Hose Replacement (LR4, LM7, LQ4 w/ Denso)»(ref-235300-S28102204062006061900000) .
  9. Discard the sealing washers. Cap all of the openings.
  10. Disconnect the electrical connections.
  11. Remove the A/C compressor mounting bolts. The lower right bolt will stay with the compressor due to a lack of clearance.
  12. Remove the A/C compressor from the bracket through the fender well.
  13. Remove the A/C compressor from the bottom on the RWD 25 series vehicles only.
  14. Drain, measure, and dispose of the compressor oil.

Installation Procedure

  1. Fill the compressor with oil. Refer to «Compressor Oil Level Check»(ref-235300-S35161970812006061900000) .
  2. Install the A/C compressor to the bracket through the fender well. Insert the mounting bolt into the lower right mounting boss before installing the A/C compressor.
  3. Install the A/C compressor to the bracket from the bottom. Insert the mounting bolt into the lower right mounting boss before installing the A/C compressor.
  4. Install the A/C compressor mounting bolts. Tighten: Tighten the mounting bolts to 50 N.m (37 lb ft).
  5. Connect the electrical connection.
  6. Install the refrigerant hose to the compressor using new sealing washers. Refer to «Compressor Hose Assembly Replacement (L35 w/ Harrison)»(ref-235300-S00957335692006061900000) or «Compressor Hose Assembly Replacement (LR4, LM7, LQ4 w/ Harrison)»(ref-235300-S22526607072006061900000) .
  7. Install the discharge hose. Refer to «Discharge Hose Replacement (LR4, LM7, LQ4 w/ Denso)»(ref-235300-S22317495672006061900000) .
  8. Install the suction hose. Refer to «Suction Hose Replacement (LR4, LM7, LQ4 w/ Denso)»(ref-235300-S28102204062006061900000) .
  9. Install the inner fender skirt.
  10. Install the right front tire and wheel assembly.
  11. Lower the vehicle.
  12. Install the drive belt.
  13. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  14. Inspect the system for leaks. Refer to «Leak Testing»(ref-235300-S02610545292006061900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Remove the drive belt.
  3. Remove the air conditioning (A/C) compressor hose assembly. Refer to «Compressor Hose Assembly Replacement (L35 w/ Harrison)»(ref-235300-S00957335692006061900000) or «Compressor Hose Assembly Replacement (LR4, LM7, LQ4 w/ Harrison)»(ref-235300-S22526607072006061900000) .
  4. Disconnect the electrical connectors as necessary.
  5. Remove the (A/C) compressor mounting bolts.
  6. Remove the (A/C) compressor from the bracket.
  7. Drain, measure, and dispose of the compressor oil.
  1. Fill the compressor with oil. Refer to «Compressor Oil Level Check»(ref-235300-S35161970812006061900000) .
  2. Install the compressor into the bracket.
  3. Install the compressor bolts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  4. Install the A/C compressor hose assembly. Refer to «Compressor Hose Assembly Replacement (L35 w/ Harrison)»(ref-235300-S00957335692006061900000) or «Compressor Hose Assembly Replacement (LR4, LM7, LQ4 w/ Harrison)»(ref-235300-S22526607072006061900000) .
  5. Connect the electrical connections.
  6. Install the drive belt.
  7. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  8. Inspect the system for leaks. Refer to «Leak Testing»(ref-235300-S02610545292006061900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Remove the serpentine drive belt.
  3. Raise and support the vehicle.
  4. Remove the right front tire and wheel assembly.
  5. Remove the inner fender skirt.
  6. Remove the compressor/condenser hose. Refer to «Compressor Hose Assembly Replacement (L35 w/ Harrison)»(ref-235300-S00957335692006061900000) or «Compressor Hose Assembly Replacement (LR4, LM7, LQ4 w/ Harrison)»(ref-235300-S22526607072006061900000) .
  7. Discard the sealing washers. Cap all of the openings.
  8. Disconnect the electrical connections.
  9. Remove the A/C compressor mounting bolts. The lower right bolt will stay with the compressor due to a lack of clearance.
  10. Remove the A/C compressor from the bracket through the fender well.
  11. Remove the A/C compressor from the bottom on the RWD 25 series vehicles only.
  12. Drain, measure, and dispose of the compressor oil.
  1. Fill the compressor with oil. Refer to «Compressor Oil Level Check»(ref-235300-S35161970812006061900000) .
  2. Install the A/C compressor to the bracket through the fender well. Insert the mounting bolt into the lower right mounting boss before installing the A/C compressor.
  3. Install the A/C compressor to the bracket from the bottom. Insert the mounting bolt into the lower right mounting boss before installing the A/C compressor.
  4. Install the A/C compressor mounting bolts. Tighten: Tighten the mounting bolts to 50 N.m (37 lb ft).
  5. Connect the electrical connection.
  6. Install the refrigerant hose to the compressor using new sealing washers. Refer to «Compressor Hose Assembly Replacement (L35 w/ Harrison)»(ref-235300-S00957335692006061900000) or «Compressor Hose Assembly Replacement (LR4, LM7, LQ4 w/ Harrison)»(ref-235300-S22526607072006061900000) .
  7. Install the inner fender skirt.
  8. Install the right front tire and wheel assembly.
  9. Lower the vehicle.
  10. Install the drive belt.
  11. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  12. Inspect the system for leaks. Refer to «Leak Testing»(ref-235300-S02610545292006061900000) .

Compressor Clutch Plate and Hub Assembly Removal

Tools Required

  1. J 34992 Compressor Holding Fixture. See «Special Tools»(ref-235300-S01064053572006061900000) .
  2. J 33013-B Clutch Plate and Hub Assembly Installer-Remover. See «Special Tools»(ref-235300-S01064053572006061900000) .
  1. Clamp the J 34992 in a vise. See «Special Tools»(ref-235300-S01064053572006061900000) .
  2. Use thumb screws in order to attach the compressor to the holding fixture.
  3. Ensure that the center screw forces the tip to thrust against the end of the shaft.
  4. Thread the J 33013-B into the hub. See «Special Tools»(ref-235300-S01064053572006061900000) .
  5. While holding the body of J 33013-B of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly (1). See «Special Tools»(ref-235300-S01064053572006061900000) .
  6. Remove the shaft key. Retain the shaft key for reassembly.

Clutch Rotor and/or Bearing Removal

Tools Required

  1. J 6083 Snap Ring Pliers. See «Special Tools»(ref-235300-S01064053572006061900000) .
  2. J 33023-A Puller Pilot. See «Special Tools»(ref-235300-S01064053572006061900000) .
  3. J 41552 Pulley Puller. See «Special Tools»(ref-235300-S01064053572006061900000) .
  4. J 29886 Driver Handle. See «Special Tools»(ref-235300-S01064053572006061900000) .
  5. J 9398-A Bearing Remover. See «Special Tools»(ref-235300-S01064053572006061900000) .
  1. Remove the clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal»(ref-235300-S32122715592006061900000) .
  2. Use the J 6083 in order to remove the following components:. See «Special Tools»(ref-235300-S01064053572006061900000) . The pulley rotor (1) The bearing assembly retaining ring (2)
  3. Install the J 33023-A to the front head. See «Special Tools»(ref-235300-S01064053572006061900000) .
  4. Install the J 41552 down into the inner circle of slots (1) in the rotor. See «Special Tools»(ref-235300-S01064053572006061900000) .
  5. Turn the J 41552 clockwise in the slots in the rotor. See «Special Tools»(ref-235300-S01064053572006061900000) .
  6. Perform the following steps in order to remove the pulley rotor and bearing assembly: Hold the J 41552 in position. See «Special Tools»(ref-235300-S01064053572006061900000) . Tighten the puller screw against the puller guide. Remove the pulley rotor and bearing assembly.
  7. Use the following procedure in order to properly support the rotor hub during bearing removal in order to prevent pulley rotor damage: Remove the forcing screw from the J 41552 . See «Special Tools»(ref-235300-S01064053572006061900000) . Ensure that the puller tangs still engage in the rotor slots. Invert the assembly onto a solid flat surface or blocks.
  8. Use the J 9398-A and the J 29886 in order to drive the bearing out of the rotor hub. See «Special Tools»(ref-235300-S01064053572006061900000) .

Compressor Clutch Coil Removal (Harrison)

Tools Required

  1. J 6083 Snap Ring Pliers. See «Special Tools»(ref-235300-S01064053572006061900000) .
  2. J 33023-A Puller Pilot. See «Special Tools»(ref-235300-S01064053572006061900000) .
  3. J 41552 Pulley Puller. See «Special Tools»(ref-235300-S01064053572006061900000) .
  4. J 8433-1 Puller Bar. See «Special Tools»(ref-235300-S01064053572006061900000) .
  5. J 33025 Clutch Coil Puller Legs. See «Special Tools»(ref-235300-S01064053572006061900000) .
  6. J 8433-3 Forcing Screw. See «Special Tools»(ref-235300-S01064053572006061900000) .
  1. Remove the clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal»(ref-235300-S32122715592006061900000) .
  2. Use the J 6083 in order to remove the following components:. See «Special Tools»(ref-235300-S01064053572006061900000) . The pulley rotor (1) The bearing assembly retaining ring (2)
  3. Install the J 33023-A to the front head. See «Special Tools»(ref-235300-S01064053572006061900000) .
  4. Install the J 41552 down into the inner circle of slots (1) in the rotor. See «Special Tools»(ref-235300-S01064053572006061900000) .
  5. Turn the J 41552 clockwise in the slots in the rotor. See «Special Tools»(ref-235300-S01064053572006061900000) .
  6. Perform the following steps in order to remove the pulley rotor and bearing assembly: Hold the J 41552 in position. See «Special Tools»(ref-235300-S01064053572006061900000) . Tighten the puller screw against the puller guide. Remove the pulley rotor and bearing assembly.
  7. Mark the clutch coil terminal location (1) on the compressor front head.
  8. Install the J 33023-A on the front head of the compressor. See «Special Tools»(ref-235300-S01064053572006061900000) .
  9. Install the J 8433-1 and the J 33025 . See «Special Tools»(ref-235300-S01064053572006061900000) .
  10. Tighten the J 8433-3 against the puller pilot in order to remove the clutch coil (2). See «Special Tools»(ref-235300-S01064053572006061900000) .

Compressor Clutch Coil Removal (Denso)

  1. Remove the clutch plate retaining bolt (1).
  2. Remove the clutch plate assembly.
  3. Remove the clutch hub/bearing snap ring.
  4. Remove the clutch hub/bearing assembly.
  5. Remove the clutch coil connector bracket retaining screw.
  6. Remove the clutch coil snap ring.
  7. Remove the clutch coil assembly.

Compressor Pressure Relief Valve Removal

Tools Required

J 39500-B R-134a A/C Refrigerant Recovery, Recycling and Recharging System (ACR4). See Special Tools .

  1. Recover the refrigerant using the J 39500-B . See «Special Tools»(ref-235300-S01064053572006061900000) .
  2. Remove the old pressure relief valve (5).

Compressor Control Switches Removal

Tools Required

  1. J 39500-B R-134a A/C Refrigerant Recovery, Recycling and Recharging System (ACR4). See «Special Tools»(ref-235300-S01064053572006061900000) .
  2. J 5403 Snap Ring Pliers. See «Special Tools»(ref-235300-S01064053572006061900000) .
  3. J 9553-01 O-Ring Remover. See «Special Tools»(ref-235300-S01064053572006061900000) .
  1. Recover the refrigerant using the J 39500-B . See «Special Tools»(ref-235300-S01064053572006061900000) .
  2. Disconnect the electrical connector from the switch (4) in the rear head of the compressor.
  3. Remove the switch retaining ring using the J 5403 . See «Special Tools»(ref-235300-S01064053572006061900000) .
  4. Remove the switch (4) from the compressor.
  5. Remove the old O-ring seal from the switch cavity using the J 9553-01 . See «Special Tools»(ref-235300-S01064053572006061900000) .
  6. Inspect the switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the components as necessary.
  1. Remove the A/C compressor. Refer to «Compressor Replacement (LR4, LM7, LQ4 w/ Denso )»(ref-235300-S33665819832006061900000) or «Compressor Replacement (L35 w/ Harrison)»(ref-235300-S34715032562006061900000) or «Compressor Replacement (LR4, LM7, LQ4 w/Harrison)»(ref-235300-S37129771702006061900000) .
  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 (LR4, LM7, LQ4 w/ Denso )»(ref-235300-S33665819832006061900000) or «Compressor Replacement (L35 w/ Harrison)»(ref-235300-S34715032562006061900000) or «Compressor Replacement (LR4, LM7, LQ4 w/Harrison)»(ref-235300-S37129771702006061900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Remove the refrigerant hose mounting bolt.
  3. Remove the refrigerant hose from the compressor.
  4. Remove the nut at the accumulator.
  5. Remove the hose from the accumulator.
  6. Remove the upper radiator baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Upper) in Engine Cooling.
  7. Remove the nut at the condenser.
  8. Remove the hose from the condenser.
  9. Disconnect the automatic recirculation electrical connector from the compressor/condenser hose.
  10. Remove the air conditioning (A/C) compressor/condenser hose assembly.
  11. Discard all of the used sealing washers. Cap the system openings.
  1. Install the A/C compressor/condenser hose assembly.
  2. Install the hose to the condenser using new sealing washers.
  3. Connect the automatic recirculation electrical connector to the compressor/condenser hose.
  4. Install the upper radiator baffle. Refer to Radiator Air Baffle Assemblies and Deflectors (Side) Radiator Air Baffle Assemblies and Deflectors (Upper) in Engine Cooling.
  5. Install the nut at the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  6. Install the hose to the accumulator using new sealing washers.
  7. Install the nut at the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  8. Install the refrigerant hose mounting bolt. Tighten: Tighten the nut to 34 N.m (25 lb ft).
  9. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  10. Inspect the system for leaks. Refer to «Leak Testing»(ref-235300-S02610545292006061900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Remove the refrigerant hose mounting bolt.
  3. Remove the refrigerant hose from the compressor.
  4. Remove the nut at the accumulator.
  5. Remove the hose from the accumulator.
  6. Remove the upper radiator baffle.
  7. Remove the nut at the condenser.
  8. Remove the hose from the condenser.
  9. Disconnect the automatic recirculation electrical connector from the compressor/condenser hose.
  10. Remove the air conditioning (A/C) compressor/condenser hose assembly.
  11. Discard all of the used sealing washers. Cap the system openings.
  1. Install the A/C compressor/condenser hose assembly.
  2. Connect the automatic recirculation electrical connector to the compressor/condenser hose.
  3. Install the hose to the condenser using new sealing washers.
  4. Install the nut at the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install the upper radiator baffle.
  6. Install the hose to the accumulator using new sealing washers.
  7. Install the nut at the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  8. Install the refrigerant hose mounting bolt. Tighten: Tighten the nut to 34 N.m (25 lb ft).
  9. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  10. Inspect the system for leaks. Refer to «Leak Testing»(ref-235300-S02610545292006061900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Remove the discharge hose mounting bolt from the compressor.
  3. Remove the discharge hose from the compressor.
  4. Remove the upper radiator baffle.
  5. Remove the nut at the condenser.
  6. Remove the discharge hose from the condenser.
  7. Disconnect the automatic recirculation electrical connector from the discharge hose.
  8. Remove the discharge hose assembly from the vehicle.
  9. Discard all of the used sealing washers. Cap the system openings.
  1. Install the discharge hose assembly to the vehicle.
  2. Connect the automatic recirculation electrical connector to the discharge hose.
  3. Install the hose to the condenser using new sealing washers.
  4. Install the nut at the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install the upper baffle.
  6. Install the discharge hose to the compressor using new sealing washers.
  7. Install the discharge hose mounting bolt. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  8. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  9. Inspect the system for leaks. Refer to «Leak Testing»(ref-235300-S02610545292006061900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Remove the suction hose mounting bolt from the compressor.
  3. Remove the suction hose from the compressor.
  4. Remove the nut at the accumulator.
  5. Remove the 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 assembly to the vehicle.
  2. Install the hose to the accumulator using new sealing washers.
  3. Install the nut at the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  4. Install the suction hose to the compressor using new sealing washers.
  5. Install the suction hose mounting bolt. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  6. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  7. Inspect the system for leaks. Refer to «Leak Testing»(ref-235300-S02610545292006061900000) .
  1. Drain the engine coolant.
  2. Disconnect the electrical connector from the air inlet duct.
  3. Remove the PCV hose from the air cleaner.
  4. Remove the air inlet assembly.
  5. Remove the radiator. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) in Engine Cooling.
  6. Recover the refrigerant from the system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) in Engine Cooling.
  7. Remove the compressor discharge hose assembly from the condenser. Refer to «Compressor Hose Assembly Replacement (L35 w/ Harrison)»(ref-235300-S00957335692006061900000) or «Compressor Hose Assembly Replacement (LR4, LM7, LQ4 w/ Harrison)»(ref-235300-S22526607072006061900000) .
  8. Remove the discharge hose. Refer to «Discharge Hose Replacement (LR4, LM7, LQ4 w/ Denso)»(ref-235300-S22317495672006061900000) .
  9. Remove the evaporator tube from the condenser.
  10. Remove the insulator retainer bolts and the upper insulator retainers.
  11. Remove the condenser.
  1. Install the condenser.
  2. Install the upper insulator retainers and the insulator retainer bolts. Tighten: Tighten the bolts to 2.4 N.m (21 lb in).
  3. Install the evaporator tube to the condenser.
  4. Install the discharge hose. Refer to «Discharge Hose Replacement (LR4, LM7, LQ4 w/ Denso)»(ref-235300-S22317495672006061900000) .
  5. Install the compressor discharge hose assembly to the condenser. Refer to «Compressor Hose Assembly Replacement (L35 w/ Harrison)»(ref-235300-S00957335692006061900000) or «Compressor Hose Assembly Replacement (LR4, LM7, LQ4 w/ Harrison)»(ref-235300-S22526607072006061900000) .
  6. Install the radiator.
  7. Install the air inlet assembly.
  8. Connect the PCV hose to the air cleaner.
  9. Connect the electrical connector to the air inlet duct.
  10. Fill the engine coolant.
  11. Add refrigerant to the system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  12. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400 . See «Special Tools»(ref-235300-S01064053572006061900000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Disconnect the electrical connector from the A/C low pressure switch.
  3. Remove the compressor hose nut from the accumulator.
  4. Remove the compressor hose from the accumulator.
  5. Remove the nut (2) from the evaporator fitting.
  6. Remove the accumulator bracket nut (4) from the retaining stud.
  7. Remove the accumulator (3).
  8. Remove the retaining bracket bolt (5).
  9. Remove the retaining bracket (6) from the accumulator.
  10. Remove and discard the O-ring seals.
  1. Install new O-ring seals.
  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. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  11. Leak test the fittings of the component using the J 39400-A .
  1. Drain the engine coolant.
  2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  3. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-235300-S35693073242006061900000) .
  4. Remove the HVAC module screws.
  5. Separate the HVAC module.
  6. Remove the evaporator core.
  1. Install the evaporator core.
  2. Install the HVAC module halves.
  3. Install the HVAC module screws. Tighten: Tighten the HVAC module screws to 1.6 N.m (14 lb in).
  4. Install the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-235300-S35693073242006061900000) .
  5. Refill the engine coolant.
  6. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  1. If equipped, remove the IP sound insulator. Refer to Insulator Replacement - Instrument Panel (I/P) 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.
  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) in Instrument Panel, Gages, and Console.
  1. Remove the blower motor insulating cover screws.
  2. Disconnect the electrical connector from the blower motor.
  3. Remove the blower motor insulating cover.
  4. Pull the retaining tab down while turning the blower motor counter-clockwise in order to disengage the blower motor from the heater/ventilation module.
  5. 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).
  1. Remove the IP carrier. Refer to «INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT»(ref-8999-S32355164262011121500000) .
  2. Remove the air distribution duct retaining screws.
  3. Remove the air distribution duct.
  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-8999-S32355164262011121500000) .
  1. Remove the IP carrier. Refer to «INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT»(ref-8999-S32355164262011121500000) .
  2. Remove the air tube from the side window outlet duct.
  3. Remove the side window air outlet duct.
  1. Install the side window air outlet duct.
  2. Install the air tube to the side window outlet duct.
  3. Install the IP carrier. Refer to «INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT»(ref-8999-S32355164262011121500000) .
  1. Remove the instrument panel (IP) bezel. Refer to Bezel Replacement - Instrument Panel (I/P) Cluster in Instrument Panel, Gauges and Console.
  2. Remove the knee bolster. Refer to Knee Bolster Replacement (Non-Luxury) .
  3. Remove the air outlet housing from the IP carrier.
  4. Disconnect the electrical connections as necessary.
  5. Remove the air outlet housing.
  6. Remove the air outlet from the housing assembly.
  7. Transfer the switch assemblies as necessary.
  1. Install the air outlet to the housing assembly.
  2. Connect the electrical connections as necessary.
  3. Push the air outlet housing into the IP carrier until the outlet housing snaps into place.
  4. Install the knee bolster. Refer to Knee Bolster Replacement (Non-Luxury) .
  5. Install the instrument panel (IP) bezel. Refer to Bezel Replacement - Instrument Panel (I/P) Cluster in Instrument Panel, Gauges and Console.
  1. Remove the instrument panel (IP) bezel. Refer to Bezel Replacement - Instrument Panel (I/P) Cluster in Instrument Panel, Gauges and Console.
  2. Remove the IP trim pad. Refer to Trim Pad Replacement - Instrument Panel (I/P) Upper in Instrument Panel, Gauges and Console.
  3. Remove the air outlet mounting screw.
  4. Remove the air outlet.
  1. Install the air outlet.
  2. Install the air outlet mounting screw. Tighten: Tighten the screw to 1.6 N.m (14 lb in).
  3. Install the IP trim pad. Refer to Trim Pad Replacement - Instrument Panel (I/P) Upper in Instrument Panel, Gauges and Console.
  4. Install the instrument panel (IP) bezel. Refer to Bezel Replacement - Instrument Panel (I/P) Cluster in Instrument Panel, Gauges and Console.
  1. Firmly pull the air outlet to the left in order to release the outlet from the instrument panel.
  2. Remove the air outlet.
  1. Install the air outlet.
  2. Push the air outlet into the instrument panel until the outlet snaps into place.
  1. Firmly pull the air outlet to the left in order to release the outlet from the instrument panel.
  2. Remove the air outlet.
  1. Install the air outlet.
  2. Push the outlet into the instrument panel until the outlet snaps into place.
  1. Remove the heater/ventilation module. Refer to «Heater Core Replacement»(ref-235300-S09064431922006061900000) .
  2. Remove the floor air outlet screws.
  3. Remove the floor air outlet (1).
  1. Install the floor air outlet.
  2. Install the floor air outlet screws (1). Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Install the heater/ventilation module. Refer to «Heater Core Replacement»(ref-235300-S09064431922006061900000) .
  1. Remove the floor console. Refer to Console Replacement (Base Console) Console Replacement (Console w/ Extension) in Instrument Panel, Gages and Console.
  2. Remove the seats. Refer to Seat Replacement - Center in Seats.
  3. Remove the HVAC module. Refer to «Heater Core Replacement»(ref-235300-S09064431922006061900000) .
  4. Roll the carpeting back to expose the rear floor air ducts.
  5. Remove the rear floor ducts from the floor studs.
  6. Remove the rear floor duct.
  1. Install the rear floor air duct.
  2. Install the rear floor ducts from the floor studs.
  3. Position the carpeting back into place.
  4. Install the HVAC module. Refer to «Heater Core Replacement»(ref-235300-S09064431922006061900000) .
  5. Install the seats. Refer to Seat Replacement - Center in Seats.
  6. Install the floor console. Refer to Console Replacement (Base Console) Console Replacement (Console w/ Extension) in Instrument Panel, Gages and Console.
  1. Disconnect the negative battery cable.
  2. Remove the heater/ventilation module. Refer to «Heater/Vent Module Replacement»(ref-235300-S35693073242006061900000)
  3. Remove the heater/ventilation module screws.
  4. Separate the heater/ventilation module halves.
  5. Remove the temperature valve.
  1. Install the temperature valve.
  2. Install the heater/ventilation module halves.
  3. Install the heater/ventilation module screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  4. Install the heater/ventilation module. Refer to «Heater/Vent Module Replacement»(ref-235300-S35693073242006061900000) .
  5. Connect the negative battery cable. Tighten: Tighten the bolt to 17 N.m (13 lb ft).
  1. Disconnect the negative battery cable.
  2. Remove the heater/ventilation module. Refer to «Heater/Vent Module Replacement»(ref-235300-S35693073242006061900000) .
  3. Remove the heater/ventilation module screws.
  4. Separate the heater/ventilation module.
  5. Remove the mode actuator cam assembly.
  6. Remove the lower mode lever.
  7. Remove the heater/defroster valve lever.
  8. Remove the lower mode valve.
  9. Remove the heater/defroster valve.
  1. Install the heater/defroster valve.
  2. Install the lower mode valve.
  3. Install the lower mode valve lever.
  4. Install the heater/defroster valve.
  5. Install the heater/defroster valve lever.
  6. Install the heater/ventilation module halves.
  7. Install the heater/ventilation module screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  8. Install the heater/ventilation module. Refer to «Heater/Vent Module Replacement»(ref-235300-S35693073242006061900000) .
  9. Connect the negative battery cable. Tighten: Tighten the bolt to 17 N.m (13 lb ft).
  1. Drain the cooling system.
  2. Remove the air intake tube.
  3. Using the J 43181 disconnect the heater hoses from the heater core inlet and outlet. See «Special Tools»(ref-235300-S01064053572006061900000) . Install the J 43181 to the heater core pipes. See «Special Tools»(ref-235300-S01064053572006061900000) . Close the tool around the heater core pipes. 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 inlet heater hose from the engine.
  5. Remove the outlet heater hose mounting bolt.
  6. Remove the outlet heater hose from the water pump.
  7. Remove the heater hoses.
  1. Install the heater hoses.
  2. Install the outlet heater hose to the engine water pump.
  3. Install the heater hose mounting bolt. Tighten: Tighten the mounting bolt to 25 N.m (18 lb ft).
  4. Install the inlet heater hose to the engine.
  5. Connect the heater hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  6. Install the air intake tube.
  7. Fill the cooling system.
  8. Inspect the cooling system for leaks.
  1. Drain the cooling system.
  2. Remove the air intake tube.
  3. Remove the heater and surge tank hoses from the mounting clip.
  4. Using the J 43181 disconnect the heater hoses from the heater core inlet and outlet. See «Special Tools»(ref-235300-S01064053572006061900000) . Install the J 43181 to the heater core pipes. See «Special Tools»(ref-235300-S01064053572006061900000) . Close the tool around the heater core pipes. 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 water pump.
  6. Remove the heater hose.
  1. Install the heater hose.
  2. Install the heater hose to the water pump.
  3. 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.
  4. Install the heater and surge tank hoses to the mounting clip.
  5. Install the air intake tube.
  6. Fill the cooling system.
  7. Inspect the cooling system for leaks.
  1. Drain the engine coolant.
  2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  3. Remove the heater/vent module. Refer to «Heater/Vent Module Replacement»(ref-235300-S35693073242006061900000) .
  4. Remove the heater core cover screws.
  5. Remove the heater core cover.
  6. Remove the heater core.
  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-235300-S35693073242006061900000) .
  5. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  6. Refill the engine coolant.
  1. Drain the engine coolant.
  2. If equipped remove the auxiliary battery.
  3. Disconnect the heater hoses. Refer to «Heater Hoses Replacement (L35)»(ref-235300-S20037704672006061900000) or «Heater Hoses Replacement (LR4, LM7, LQ4)»(ref-235300-S23294041002006061900000) .
  4. Remove the accumulator. Refer to «Accumulator Replacement»(ref-235300-S02215623882006061900000) .
  5. Remove the instrument panel carrier. Refer to «INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT»(ref-8999-S32355164262011121500000) .
  6. Remove the HVAC module drain hose.
  7. Disconnect the electrical harnesses and the ground connections as needed.
  8. Remove the mounting nuts and the screws from the HVAC module.
  9. Remove the HVAC module assembly from the vehicle.
  1. If you are replacing the HVAC module, transfer the components from the old HVAC module as necessary.
  2. Install the HVAC module assembly to the vehicle.
  3. Install the mounting nuts and the screws to the HVAC module. Tighten: Tighten the mounting screws to 4 N.m (35 lb in). Tighten the mounting nuts to 9 N.m (80 lb in).
  4. Connect the electrical harnesses and the ground connections.
  5. Install the HVAC module drain hose.
  6. Install the instrument panel carrier. Refer to «INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT»(ref-8999-S32355164262011121500000) .
  7. Install the accumulator. Refer to «Accumulator Replacement»(ref-235300-S02215623882006061900000) .
  8. Connect the heater hoses. Refer to «Heater Hoses Replacement (L35)»(ref-235300-S20037704672006061900000) or «Heater Hoses Replacement (LR4, LM7, LQ4)»(ref-235300-S23294041002006061900000) .
  9. Install the auxiliary battery.
  10. Fill the cooling system.
  1. Drain the cooling system.
  2. Remove the auxiliary heater pipes (1,2) from the heater inlet and outlet tees (3,4).
  3. Loosen the right front wheelhouse to gain access to the clamp behind the wheelhouse.
  4. Raise the vehicle.
  5. Remove the auxiliary heater pipes (2,3) from the auxiliary heater core.
  6. Remove the heater/A/C tubes retaining nut (4) from the stud (1) at the frame (6).
  7. Remove the auxiliary heater pipes (2) from the clamps (5).
  8. Remove the auxiliary heater pipes from the vehicle.
  1. Install the auxiliary heater pipes to the vehicle.
  2. Install the auxiliary heater pipes (2) to the clamps (5).
  3. Install the heater/A/C tubes retaining nut (4) to the stud (1) at the frame (6). Tighten: Tighten the heater/A/C tubes retaining nut to 7 N.m (62 lb in).
  4. Install the auxiliary heater pipes (2,3) to the auxiliary heater core.
  5. Lower the vehicle.
  6. Install the right front wheelhouse.
  7. Install the auxiliary heater pipes (1,2) to the heater inlet and outlet tees (3,4).
  8. Fill the cooling system.
  1. Remove the right rear quarter trim panel.
  2. Disconnect the electrical connectors.
  3. Remove the blower motor screws.
  4. Remove the blower motor (1) from the auxiliary HVAC module (2).
  5. Remove the retaining clip from the fan cage.
  6. Remove the fan cage from the blower motor.
  1. Install the fan cage to the blower motor (1).
  2. Install the retaining clip to the fan cage.
  3. Install the blower motor (1) to the auxiliary HVAC module (2).
  4. Install the blower motor screws.
  5. Connect the electrical connectors.
  6. Install the right rear quarter trim.
  1. Remove the right rear quarter trim panel.
  2. Disconnect the electrical connector from the actuator (1).
  3. Remove the retaining screws from the actuator (1).
  4. Remove the mode actuator (1) from the vehicle.
  1. Install the mode actuator (1) to the vehicle.
  2. Install the retaining screws to the actuator (1).
  3. Connect the electrical connector to the actuator (1).
  4. Install the left rear quarter trim panel.
  1. Remove the right rear quarter trim panel.
  2. Disconnect the electrical connector from the actuator (1).
  3. Remove the retaining screws from the actuator (1).
  4. Remove the mode actuator (1) from the vehicle.
  1. Install the mode actuator (1) to the vehicle.
  2. Install the retaining screws to the actuator (1).
  3. Connect the electrical connector to the actuator (1).
  4. Install the right rear quarter trim panel.
  1. Remove the right rear quarter trim panel.
  2. Remove the upper air temperature sensor if equipped
  3. Remove the upper air duct fastener (5).
  4. Remove the duct (6) from the vehicle.
  1. Install the duct (6) to the vehicle.
  2. Install the upper air duct fastener (5).
  3. Install the upper air temperature sensor if equipped
  4. Install the right rear quarter trim panel.
  1. Remove the right rear quarter trim panel.
  2. Remove the air temperature sensor if equipped
  3. Remove the lower air duct fastener.
  4. Remove the lower air duct (5) from the vehicle.
  1. Install the air duct (5) to the vehicle.
  2. Install the lower air duct fastener.
  3. Install the air temperature sensor if equipped
  4. Install the left rear quarter trim panel.
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Drain the engine coolant.
  3. Raise the vehicle.
  4. Disconnect the heater lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle.
  5. Disconnect the air conditioning lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle.
  6. Remove the nuts (2) from the studs (1) that secure the auxiliary HVAC module to the underside of the vehicle.
  7. Remove the safety stands.
  8. Lower the vehicle.
  9. Remove the right rear quarter trim panel.
  10. Remove the Real Time Damping (RTD) Module.
  11. Disconnect the electrical connectors.
  12. Remove the fastener (5) for the upper auxiliary air duct (1). Carefully slide the duct up, into the headliner, until the bottom edge of the duct is above the air distributor duct.
  13. Remove the fasteners (3) retaining the rear auxiliary HVAC module to the vehicle.
  14. Remove the rear auxiliary HVAC module (4) from the vehicle and place it on a work surface.
  15. Remove the air temperature actuator (1) from the module.
  16. Remove the heater core cover (1) from the module.
  17. Remove the heater core (1) from the module.
  1. Install the heater core (1) to the module.
  2. Install the heater core cover (1) to the module.
  3. Install the air temperature actuator (1) to the module.
  4. Install the auxiliary HVAC module assembly (4) to the vehicle.
  5. Install the two bolts (3) inside the vehicle in order to retain the case to the vehicle.
  6. Install the upper auxiliary air duct (1) to the air distributor duct. Install the fastener (5).
  7. Connect the electrical connectors.
  8. Install the RTD Module.
  9. Install the right rear quarter trim panel.
  10. Raise the vehicle.
  11. Install the nuts (2) that secure the auxiliary HVAC module to the vehicle. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  12. Install the air conditioning lines (2, 3) and the nut (4) to the auxiliary HVAC module. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  13. Install the heater lines (2, 3) to the auxiliary HVAC module at the underside of vehicle.
  14. Remove the safety stands.
  15. Lower the vehicle.
  16. Fill the engine coolant.
  17. Recharge the refrigerant to the system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Drain the engine coolant.
  3. Raise the vehicle.
  4. Disconnect the heater lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle.
  5. Disconnect the air conditioning lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle.
  6. Remove the nuts (2) from the studs (1) that secure the auxiliary HVAC module to the underside of the vehicle.
  7. Remove the safety stands.
  8. Lower the vehicle.
  9. Remove the right rear quarter trim panel.
  10. Remove the Real Time Damping (RTD) Module.
  11. Disconnect the electrical connectors.
  12. Remove the fastener (5) for the upper auxiliary air duct (6). Carefully slide the duct up, into the headliner, until the bottom edge of the duct is above the air distributor duct.
  13. Remove the fastener (4) for the lower auxiliary air outlet (5).
  14. Remove the fastener (4) for the air distributor duct (3). Remove the air distributor duct (3).
  15. Remove the fasteners (2, 4) retaining the rear auxiliary HVAC module to the vehicle.
  16. Remove the rear auxiliary HVAC module (3) from the vehicle and place it on a work surface.
  17. Remove the air temperature actuator (1) from the module.
  18. Remove the stud on the underside of the rear HVAC module between the heater core inlet and outlet pipes.
  19. Carefully separate the heater core pipe gasket from the module case and remove the heater core pipe retainer.
  20. Remove the rear HVAC module lower cover.
  21. Remove the heater core clamp.
  22. Remove the heater core from the module.
  1. Install the heater core to the module.
  2. Install the heater core clamp.
  3. Install the rear HVAC module lower cover.
  4. Install the heater core pipe retainer and gasket.
  5. Install the stud between the heater core inlet and outlet on the underside of the rear HVAC module.
  6. Install the air temperature actuator (1) to the module.
  7. Install the auxiliary HVAC module assembly (3) to the vehicle.
  8. Install the two bolts (2, 4) inside the vehicle in order to retain the case to the vehicle.
  9. Install the air distributor duct (3) and fastener (4).
  10. Install the lower auxiliary air outlet (5) and fastener (4).
  11. Install the upper auxiliary air duct (6) to the air distributor duct (3). Install the fastener (5).
  12. Connect the electrical connectors.
  13. Install the RTD Module.
  14. Install the right rear quarter trim panel.
  15. Raise the vehicle.
  16. Install the nuts (2) that secure the auxiliary HVAC module to the vehicle. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  17. Install the air conditioning lines (2, 3) and the nut (4) to the auxiliary HVAC module. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  18. Install the heater lines (2, 3) to the auxiliary HVAC module at the underside of vehicle.
  19. Remove the safety stands.
  20. Lower the vehicle.
  21. Fill the engine coolant.
  22. Recharge the refrigerant to the system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  1. Remove the right rear quarter trim panel.
  2. Disconnect the electrical connector from the blower motor resistor.
  3. Remove the retaining screws from the blower motor resistor.
  4. Remove the blower motor resistor (1) from the vehicle.
  1. Install the blower motor resistor (1) to the vehicle.
  2. Install the retaining screws to the blower motor resistor.
  3. Connect the electrical connector to the blower motor resistor.
  4. Install the right rear quarter trim panel.
  1. Remove the evaporator core. Refer to «Evaporator Core Replacement - Auxiliary (Tahoe/Yukon)»(ref-235300-S17301429712006061900000) or «Evaporator Core Replacement - Auxiliary (Suburban/Yukon XL)»(ref-235300-S35033019912006061900000) .
  2. Carefully remove the sealer packed around the Thermal Expansion Valve (TXV). Reuse the sealer on the replacement TXV.
  3. Remove the clip retaining the capillary tube to the evaporator core.
  4. Disconnect the evaporator tube connections from the TXV.
  5. Remove the TXV from the tubes.
  1. Install the TXV to the tubes.
  2. Connect the evaporator tube connections from the TXV. Tighten: Tighten the tube connections to 28 N.m (21 lb ft).
  3. Install the clip in order to retain the capillary tube to the evaporator core.
  4. Pack sealer around the TXV in the manner found during the disassembly.
  5. Install the evaporator core. Refer to «Evaporator Core Replacement - Auxiliary (Tahoe/Yukon)»(ref-235300-S17301429712006061900000) or «Evaporator Core Replacement - Auxiliary (Suburban/Yukon XL)»(ref-235300-S35033019912006061900000) .
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Drain the engine coolant.
  3. Raise the vehicle.
  4. Disconnect the heater lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle.
  5. Disconnect the air conditioning lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle.
  6. Remove the nuts (2) from the studs (1) that secure the auxiliary HVAC module to the underside of the vehicle.
  7. Remove the safety stands.
  8. Lower the vehicle.
  9. Remove the right rear quarter trim panel.
  10. Remove the Real Time Damping (RTD) Module.
  11. Disconnect the electrical connectors.
  12. Remove the fastener (5) for the upper auxiliary air duct (1). Carefully slide the duct up, into the headliner, until the bottom edge of the duct is above the air distributor duct.
  13. Remove the fasteners (3) retaining the rear auxiliary HVAC module to the vehicle.
  14. Remove the rear auxiliary HVAC module (4) from the vehicle and place it on a work surface.
  15. Remove the air temperature actuator (1) from the module.
  16. Remove the heater core cover (1) from the module.
  17. Remove the heater core (1) from the module.
  18. Remove the lower module cover from the module.
  19. Remove the evaporator core from the lower module cover.
  1. Install the evaporator core to the lower module cover.
  2. Install the lower module cover to the module.
  3. Install the heater core (1) to the module.
  4. Install the heater core cover (1) to the module.
  5. Install the air temperature actuator (1) to the module.
  6. Install the auxiliary HVAC module assembly (4) to the vehicle.
  7. Install the two bolts (3) inside the vehicle in order to retain the case to the vehicle.
  8. Install the upper auxiliary air duct (1) to the air distributor duct. Install the fastener (5).
  9. Connect the electrical connectors.
  10. Install the RTD Module.
  11. Install the right rear quarter trim panel.
  12. Raise the vehicle.
  13. Install the nuts (2) that secure the auxiliary HVAC module to the vehicle. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  14. Install the air conditioning lines (2, 3) and the nut (4) to the auxiliary HVAC module (1). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  15. Install the heater lines (2, 3) to the auxiliary HVAC module (1) at the underside of vehicle.
  16. Remove the safety stands.
  17. Lower the vehicle.
  18. Fill the engine coolant.
  19. Recharge the refrigerant to the system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  20. Leak test the fittings of the component using the J 39400-A .
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Drain the engine coolant.
  3. Raise the vehicle.
  4. Disconnect the heater lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle.
  5. Disconnect the air conditioning lines (2, 3) from the auxiliary HVAC module (1) at the underside of the vehicle.
  6. Remove the nuts (2) from the studs (1) that secure the auxiliary HVAC module to the underside of the vehicle (3).
  7. Remove the safety stands.
  8. Lower the vehicle.
  9. Remove the right rear quarter trim panel.
  10. Remove the Real Time Damping (RTD) Module.
  11. Disconnect the electrical connectors.
  12. Remove the fastener (5) for the upper auxiliary air duct (6). Carefully slide the duct up, into the headliner, until the bottom edge of the duct is above the air distributor duct.
  13. Remove the fastener (4) for the lower auxiliary air outlet (5).
  14. Remove the fastener (4) for the air distributor duct (3). Remove the air distributor duct (3).
  15. Remove the fasteners (2, 4) retaining the rear auxiliary HVAC module (3) to the vehicle.
  16. Remove the rear auxiliary HVAC module (3) from the vehicle and place it on a work surface.
  17. Remove the air temperature actuator (1).
  18. Remove the stud on the underside of the rear HVAC module between the heater core inlet and outlet pipes (4).
  19. Carefully separate the heater core pipe gasket from the module case and remove the heater core pipe retainer.
  20. Remove the rear HVAC module lower cover.
  21. Remove the heater core clamp.
  22. Remove the heater core from the module.
  23. Carefully remove the gasket between the rear HVAC module and the air distributor duct. This gasket will be re-used if possible.
  24. Remove the fasteners and separate the front case half from the back half.
  25. Remove the evaporator core from the back case half.
  26. Inspect the gaskets and the seals for damage.
  27. Replace the gaskets and the seals, as needed.
  1. Transfer the Thermal Expansion Valve (TXV) to the replacement evaporator core.
  2. Install the evaporator core into the case.
  3. Install the evaporator core seal.
  4. Reassemble the case halves.
  5. Install the heater core to the module.
  6. Install the heater core clamp.
  7. Install the rear HVAC module lower cover.
  8. Install the heater core pipe retainer and gasket.
  9. Install the stud between the heater core inlet and outlet on the underside of the rear HVAC module.
  10. Install the air temperature actuator (1).
  11. Install the auxiliary HVAC module (3) to the vehicle.
  12. Install the two bolts (2, 4) inside the vehicle in order to retain the HVAC module to the vehicle.
  13. Install the air distributor duct (3) and fastener (4).
  14. Install the lower auxiliary air outlet (5) and fastener (4).
  15. Install the upper auxiliary air duct (6) to the air distributor duct (3). Install the fastener (5).
  16. Connect the electrical connectors.
  17. Install the RTD Module.
  18. Install the right rear quarter trim panel.
  19. Raise the vehicle.
  20. Install the nuts (2) that secure the auxiliary HVAC module to the vehicle. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  21. Install the air conditioning lines (2, 3) and the nut (4) to the auxiliary HVAC module. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  22. Install the heater lines (2, 3) to the auxiliary HVAC module at the underside of vehicle.
  23. Remove the safety stands.
  24. Lower the vehicle.
  25. Fill the engine coolant.
  26. Recharge the refrigerant to the system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  27. Leak test the fittings of the component using the J 39400-A .
  1. Recover the refrigerant from the system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  2. Remove the auxiliary A/C evaporator tubes (3) from the condenser tube (2) and the accumulator (5).
  3. Loosen the right front wheelhouse to gain access to the clamp behind the wheelhouse.
  4. Raise the vehicle.
  5. Remove the retaining nut (2) and the auxiliary A/C evaporator tubes (3) from the auxiliary HVAC module.
  6. Remove the heater/A/C tubes retaining nut (4) from the stud (1) at the frame (6).
  7. Remove the auxiliary A/C evaporator tubes (3) from the clamps (5).
  8. Remove the auxiliary A/C evaporator tubes from the vehicle.
  1. Install the auxiliary A/C evaporator tubes to the vehicle.
  2. Install the auxiliary A/C evaporator tubes (3) to the clamps (5).
  3. Install the heater/A/C tubes retaining nut (4) to the stud (1) at the frame (6). Tighten: Tighten the heater/A/C tubes retaining nut to 7 N.m (62 lb in).
  4. Install the auxiliary A/C evaporator tubes (2,3) and the retaining nut to the auxiliary HVAC module. Tighten: Tighten the nut to 16 N.m (142 lb in).
  5. Lower the vehicle.
  6. Install the right front wheelhouse.
  7. Install the auxiliary A/C evaporator tubes (3) to the condenser tube (2) and the accumulator (5). Tighten: Tighten the nuts to 16 N.m (142 lb in).
  8. Recharge the refrigerant to the system. Refer to «Refrigerant Recovery and Recharging»(ref-235300-S36021813022006061900000) .
  9. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400 . See «Special Tools»(ref-235300-S01064053572006061900000) .
  1. Remove the right rear quarter trim panel.
  2. Disconnect the electrical connector from the temperature actuator.
  3. Remove the retaining screws from the temperature actuator.
  4. Remove the temperature actuator (1) from the rear HVAC module.
  1. Install the temperature actuator (1) to the rear HVAC module.
  2. Install the retaining screws to the temperature actuator.
  3. Connect the electrical connector to the temperature actuator.
  4. Install the right rear quarter trim panel.

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