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

Automatic HVAC System 44 illustrations ~6790 words

Balancing Procedure with Service Compressor Replacement (Flushing Not Required)

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

Balancing Procedure with Service Compressor Replacement (Flushing Required)

  1. Flush the A/C system. Flushing will remove all the oil from the A/C system. Refer to «Flushing (HP2)»(ref-364481-S00393580762010063000000) .
  2. Remove the A/C compressor from the vehicle. Refer to «Air Conditioning Compressor Replacement (HP2)»(ref-364481-S08835530192010063000000) . The A/C system must be replenished with 150 ml (5.0 oz) of POE oil. NOTE: The refrigerant oil in the A/C system must be balanced during compressor replacement. The new service compressor is shipped with 74 ml (2.5 oz) of refrigerant oil. Do not drain the oil from the compressor.
  3. Before installing the compressor, deduct the amount of oil shipped with the compressor 74 ml (2.5 oz) from the total amount of the system oil 150 ml (5.0 oz).
  4. Add the calculated amount 76 ml (2.5 oz) of oil to the compressor and install it in the vehicle.

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  2. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
  3. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-364495-S39273193582010063000000) .
  4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
  5. Remove the A/C belt from the A/C compressor.
  6. Slowly release the tension on the A/C belt tensioner.
  7. Remove the discharge hose bolt from the A/C compressor.
  8. Remove the discharge hose from the A/C compressor.
  9. Remove the suction hose bolt from the A/C compressor.
  10. Remove the suction hose from the A/C compressor.
  11. Discard the sealing washers. Cap all of the openings.
  12. Disconnect the electrical connections.
  13. Remove the A/C compressor mounting bolts. The lower right bolt (3) will stay with the compressor due to a lack of clearance.
  14. Remove the A/C compressor (2) from the bracket (1).
  15. If replacing the A/C compressor. Refer to «Air Conditioning Compressor Oil Balancing (Non-HP2)»(ref-364481-S19067308162010063000000) .

Installation Procedure

  1. Install the A/C compressor (2) to the bracket (1) through the fender well. Insert the mounting bolt (3) into the lower right mounting boss before installing the A/C compressor.
  2. Install the A/C compressor to the bracket. Insert the mounting bolt into the lower right mount before installing the A/C compressor.
  3. Install the A/C compressor mounting bolts and tighten to 50 N.m (37 lb ft).
  4. Connect the electrical connector to the A/C compressor.
  5. Install the A/C discharge hose to the compressor using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-364481-S02595102552010063000000) .
  6. Install the A/C discharge hose bolt to the A/C compressor and tighten to 16 N.m (12 lb ft).
  7. Install the A/C suction hose to the compressor using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-364481-S02595102552010063000000) .
  8. Install the A/C suction hose bolt to the A/C compressor and tighten to 16 N.m (12 lb ft).
  9. Install the A/C drive belt. Refer to «Air Conditioning Compressor Belt Replacement (V8)»(ref-364523-S10826138692010063000000) .
  10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  11. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-364495-S39273193582010063000000) .
  12. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-364481-S11510526782010063000000) .

Scheme 6

Scheme 6: Compressor Clutch Plate/Hub Assembly Replacement
Scheme 6: Compressor Clutch Plate/Hub Assembly Replacement
CalloutComponent Name
Preliminary Procedure Remove the air conditioning compressor belt. Refer to Air Conditioning Compressor Belt Replacement (V8) . Remove the air conditioning compressor if necessary. Refer to Air Conditioning Compressor Replacement (HP2) or Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG) . Disconnect the electrical connector from the air conditioning compressor.
1Air Conditioning Compressor Pulley Bolt CAUTION: Refer to Fastener Caution . Tighten: 18 N.m (13 lb ft)
2Air Conditioning Clutch Drive Plate Procedure: Measure and adjust the air conditioning compressor clutch drive plate per specification. Refer to Air Conditioning Clutch Drive Plate Adjustment .
3Air Conditioning Compressor Clutch Drive Plate Adjustment Shim
4Air Conditioning Compressor Clutch Pulley Snap Ring Procedure: Ensure the clutch pulley snap ring is installed with the flat side toward the air compressor. Note the rounded off portion of the snap ring per illustration, will be on the right side upon proper installation.
5Air Conditioning Compressor Clutch Pulley
6Air Conditioning Compressor Clutch Coil Snap Ring Procedure: Ensure the clutch coil snap ring is installed with the flat side toward the air compressor. Note the larger portion of the snap ring per illustration, will be on the right side upon proper installation.
7Air Conditioning Compressor Clutch Coil
CAUTION
Refer to Fastener Caution .
  1. Remove the A/C compressor. Refer to «Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG)»(ref-364481-S12997893232010063000000) .
  2. Remove the A/C belt tensioner bolts.
  3. Remove the A/C belt tensioner.
  4. Remove the A/C compressor bracket mounting bolts.
  5. Remove the A/C compressor bracket.
  1. Install the A/C compressor bracket.
  2. Install the A/C compressor bracket mounting bolts and tighten to 50 N.m (37 lb ft).
  3. Install the A/C belt tensioner.
  4. Install the A/C belt tensioner bolts and tighten to 50 N.m (37 lb ft).
  5. Install the A/C compressor. Refer to «Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG)»(ref-364481-S12997893232010063000000) .
  1. Remove the seal washer from the A/C refrigerant component.
  2. Inspect the seal washer for signs of damage to help determine the root cause of the failure.
  3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
  4. Discard the sealing washer.
  1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
  2. Remove the cap or tape from the A/C refrigerant components.
  3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
  4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting.
  5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.
  1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). For banjo style fittings remove the bolt retaining the banjo type fitting.
  2. Remove the O-ring seal from the A/C refrigerant component.
  3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.
  4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
  5. Cap or tape the A/C refrigerant components.
  6. Discard the O-ring seal.
  1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
  2. Remove the cap or tape from the A/C refrigerant components.
  3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.
  4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
  5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
  6. The O-ring seal must be fully seated.
  7. Assemble the A/C components. Refer to the appropriate repair procedure. For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  2. Remove the discharge hose mounting bolt (2) from the A/C compressor.
  3. Remove the discharge hose (1) from the A/C compressor.
  4. Remove the upper radiator baffle. Refer to «Radiator Air Upper Baffle and Deflector Replacement (Yukon)»(ref-364492-S32010845772010063000000) or «Radiator Air Upper Baffle and Deflector Replacement (Cadillac)»(ref-364492-S29331145472010063000000) .
  5. Remove the discharge hose nut from the condenser.
  6. Remove the discharge hose from the condenser.
  7. Disconnect the electrical connector from the A/C recirculation switch.
  8. Remove the discharge hose from the vehicle.
  9. Discard all of the used sealing washers. Cap the system openings.
  1. Install the discharge hose (1) to the vehicle.
  2. Install the discharge hose to the condenser using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-364481-S02595102552010063000000) .
  3. Install the discharge hose nut to the condenser and tighten to 16 N.m (12 lb ft).
  4. Install the upper air baffle. Refer to «Radiator Air Upper Baffle and Deflector Replacement (Yukon)»(ref-364492-S32010845772010063000000) or «Radiator Air Upper Baffle and Deflector Replacement (Cadillac)»(ref-364492-S29331145472010063000000) .
  5. Connect the electrical connector to the A/C recirculation switch.
  6. Install the discharge hose (1) to the A/C compressor using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-364481-S02595102552010063000000) .
  7. Install the discharge hose mounting bolt and tighten to 16 N.m (12 lb ft).
  8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  9. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-364481-S11510526782010063000000) .

Scheme 7

Scheme 7: Discharge Hose Replacement (HP2)
Scheme 7: Discharge Hose Replacement (HP2)
CalloutComponent Name
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. Preliminary Procedures Disable the hybrid high voltage system. Refer to High Voltage Disabling . Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) and High Voltage Enabling . Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove the radiator air upper baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (Yukon) or Radiator Air Upper Baffle and Deflector Replacement (Cadillac) . Remove the radiator side shield. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the front wheelhouse liner right side. Refer to Front Wheelhouse Liner Replacement - Right Side
1Discharge Hose Nut CAUTION: Refer to Fastener Caution . Tighten: 16 N.m (12 lb ft)
2Discharge Hose Bolt Tighten: 16 N.m (12 lb ft)
3Discharge Hose Procedure Remove and discard sealing washer. Refer to Air Conditioning System Seal Replacement . Disconnect the electrical connector. Enable the hybrid high voltage system. Refer to High Voltage Enabling .
WARNING
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death.
CAUTION
Refer to Fastener Caution .

Scheme 8

Scheme 8: Suction Hose Replacement (W/O C69-HP2)
Scheme 8: Suction Hose Replacement (W/O C69-HP2)
CalloutComponent Name
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) . Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove the radiator air upper baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (Yukon) or Radiator Air Upper Baffle and Deflector Replacement (Cadillac) . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the front wheelhouse liner right side. Refer to Front Wheelhouse Liner Replacement - Right Side
1Suction Hose Nut CAUTION: Refer to Fastener Caution . Tighten: 9 N.m (80 lb in)
2Suction Hose Bolt Tighten: 9 N.m (80 lb in)
3Suction Hose Procedure: Remove and discard sealing washer. Refer to Air Conditioning System Seal Replacement .
WARNING
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death.
CAUTION
Refer to Fastener Caution .

Scheme 9

Scheme 9: Suction Hose Replacement (W/O C69)
Scheme 9: Suction Hose Replacement (W/O C69)
CalloutComponent Name
Preliminary Procedure: Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) or Refrigerant Recovery and Recharging (Non-HP2) .
1Suction Hose Bolt CAUTION: Refer to Fastener Caution . Tighten: 9 N.m (80 lb in)
2Suction Hose Nut Tighten: 9 N.m (80 lb in)
3Sealing Washer Tip: Remove and discard sealing washer. Refer to Air Conditioning System Seal Replacement .
4A/C Suction Hose
CAUTION
Refer to Fastener Caution .

Scheme 10

Scheme 10: Suction Hose Replacement (W/C69)
Scheme 10: Suction Hose Replacement (W/C69)
CalloutComponent Name
Preliminary Procedure: Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) or Refrigerant Recovery and Recharging (Non-HP2) .
1A/C Auxiliary Suction Hose Nut CAUTION: Refer to Fastener Caution . Tighten: 9 N.m (80 lb in)
2A/C Auxiliary Suction Hose Procedure: Remove and discard sealing washer. Refer to Air Conditioning System Seal Replacement .
CAUTION
Refer to Fastener Caution .

Scheme 11

Scheme 11: Suction Hose Replacement (W/C69-HP2)
Scheme 11: Suction Hose Replacement (W/C69-HP2)
CalloutComponent Name
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) . Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove the radiator air upper baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (Yukon) or Radiator Air Upper Baffle and Deflector Replacement (Cadillac) . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the front wheelhouse liner right side. Refer to Front Wheelhouse Liner Replacement - Right Side
1Suction Hose Nut CAUTION: Refer to Fastener Caution . Tighten: 9 N.m (80 lb in)
2Evaporator Tube to Rear A/C Nut Tighten: 9 N.m (80 lb in)
3Suction Hose to Rear A/C Nut Tighten: 9 N.m (80 lb in)
4Suction Hose Procedure: Remove and discard sealing washer. Refer to Air Conditioning System Seal Replacement .
WARNING
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death.
CAUTION
Refer to Fastener Caution .

Scheme 12

Scheme 12: Air Conditioning Evaporator Tube Replacement (W/O C69 HP2)
Scheme 12: Air Conditioning Evaporator Tube Replacement (W/O C69 HP2)
CalloutComponent Name
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. Preliminary Procedures Disable the hybrid high voltage system. Refer to High Voltage Disabling . Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) and High Voltage Enabling . Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front wheelhouse lining. Refer to Front Wheelhouse Liner Replacement - Right Side Remove the radiator air upper baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (Yukon) or Radiator Air Upper Baffle and Deflector Replacement (Cadillac) . Remove the engine shield. Refer to Engine Shield Replacement . Remove the oil pan skid plate. Refer to Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) or Oil Pan Skid Plate Replacement (1500 with RPO NZZ) .
1Evaporator Tube to TXV Nut CAUTION: Refer to Fastener Caution . Tighten: 16 N.m (12 lb ft)
2Evaporator Tube to Condenser Nut Tighten: 16 N.m (12 lb ft)
3Evaporator Tube Procedure Undo coupling and remove through wheelhouse opening. Remove and discard sealing washer. Refer to Air Conditioning System Seal Replacement . Enable the hybrid high voltage system. Refer to High Voltage Enabling .
WARNING
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death.
CAUTION
Refer to Fastener Caution .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  2. Remove the upper radiator air baffle and deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement (Yukon)»(ref-364492-S32010845772010063000000) or «Radiator Air Upper Baffle and Deflector Replacement (Cadillac)»(ref-364492-S29331145472010063000000) .
  3. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-364495-S39902063342010063000000) .
  4. Remove the surge tank hold down nut and bolt and position aside.
  5. Remove the evaporator tube nut from the evaporator.
  6. Disconnect the evaporator tube from the evaporator.
  7. Remove the evaporator tube nut from the auxiliary A/C tube, if equipped.
  8. Disconnect the evaporator tube from the auxiliary A/C tube, if equipped.
  9. Remove the evaporator tube nut from the condenser.
  10. Disconnect the evaporator tube from the condenser.
  11. Remove the evaporator tube from the vehicle.
  12. Discard all of the used sealing washers. Cap all of the open connections.
  1. Connect the evaporator tube to the condenser using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-364481-S02595102552010063000000) .
  2. Install the evaporator tube nut to the condenser and tighten to 16 N.m (12 lb ft).
  3. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers, if equipped. Refer to «Air Conditioning System Seal Replacement»(ref-364481-S02595102552010063000000) .
  4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped, and tighten to 16 N.m (12 lb ft).
  5. Install the evaporator tube to the evaporator.
  6. Install the evaporator tube nut to the evaporator and tighten to 16 N.m (12 lb ft).
  7. Install the surge tank hold down nut and bolt and position aside.
  8. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-364495-S39902063342010063000000) .
  9. Install the upper radiator air baffle and deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement (Yukon)»(ref-364492-S32010845772010063000000) or «Radiator Air Upper Baffle and Deflector Replacement (Cadillac)»(ref-364492-S29331145472010063000000) .
  10. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  11. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-364481-S11510526782010063000000) .

Scheme 13

Scheme 13: Air Conditioning Evaporator Tube Replacement (W/C69 HP2)
Scheme 13: Air Conditioning Evaporator Tube Replacement (W/C69 HP2)
CalloutComponent Name
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. Preliminary Procedures Disable the hybrid high voltage system. Refer to High Voltage Disabling . Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) and High Voltage Enabling . Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front wheelhouse lining. Refer to Front Wheelhouse Liner Replacement - Right Side Remove the radiator air upper baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (Yukon) or Radiator Air Upper Baffle and Deflector Replacement (Cadillac) . Remove the engine shield. Refer to Engine Shield Replacement . Remove the oil pan skid plate. Refer to Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) or Oil Pan Skid Plate Replacement (1500 with RPO NZZ) .
1Evaporator Tube to TXV Nut CAUTION: Refer to Fastener Caution . Tip: Discard all of the used sealing washers. Tighten: 16 N.m (12 lb ft)
2Evaporator Tube to Condenser Nut. Tighten: 16 N.m (12 lb ft)
3Evaporator Tube to Rear A/C Nut Tighten: 16 N.m (12 lb ft)
4Evaporator Tube Procedure Undo coupling and remove through wheelhouse opening. Remove and discard sealing washer. Refer to Air Conditioning System Seal Replacement . Enable the hybrid high voltage system. Refer to High Voltage Enabling .
WARNING
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death.
CAUTION
Refer to Fastener Caution .

Scheme 14

Scheme 14: Air Conditioning (AC) Refrigerant Filter Replacement (C69)
Scheme 14: Air Conditioning (AC) Refrigerant Filter Replacement (C69)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) or Refrigerant Recovery and Recharging (Non-HP2) . Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
1Nut, A/C Refrigerant Filter Line CAUTION: Refer to Fastener Caution . Tighten: 9 N.m (80 lb in)
2Fitting, Pressure Line Tip: Loosen tube fitting and separate the pressure line to access the filter.
3Filter Assembly, A/C Refrigerant TXV
CAUTION
Refer to Fastener Caution .

Scheme 15

Scheme 15: Air Conditioning (AC) Refrigerant Filter Replacement (C69-HP2)
Scheme 15: Air Conditioning (AC) Refrigerant Filter Replacement (C69-HP2)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) . Raise the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the wheelhouse panel - right side. See Front Wheelhouse Liner Replacement - Right Side .
1A/C Refrigerant Filter Line Nut CAUTION: Refer to Fastener Caution . Tighten: 9 N.m (80 lb in)
2Pressure Line Fitting Tip: Loosen tube fitting and separate the pressure line to access the filter.
3O-ring Seal Tip: Remove and discard O-ring. Refer to Air Conditioning O-Ring Seal Replacement .
4A/C Refrigerant TXV Filter Assembly
CAUTION
Refer to Fastener Caution .

Scheme 16

Scheme 16: Expansion (Orifice) Tube Replacement (W/O C69)
Scheme 16: Expansion (Orifice) Tube Replacement (W/O C69)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) or Refrigerant Recovery and Recharging (Non-HP2) . Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1Orifice Tube Fitting CAUTION: Refer to Fastener Caution . Tip: Loosen orifice tub fitting and separate the pressure line to access the orifice. Tighten: 9 N.m (80 lb in)
2O-ring Seal Tip: Remove and discard O-ring. Refer to Air Conditioning O-Ring Seal Replacement .
3Orifice Tube Assembly Tip: Use J 26549-E to remove orifice tube. See Special Tools .
CAUTION
Refer to Fastener Caution .

Scheme 17

Scheme 17: Expansion (Orifice) Tube Replacement (W/C69)
Scheme 17: Expansion (Orifice) Tube Replacement (W/C69)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) or Refrigerant Recovery and Recharging (Non-HP2) . Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1Fitting, Orifice Tube CAUTION: Refer to Fastener Caution . Tighten: 9 N.m (80 lb in) Tip: It may be necessary to remove the auxiliary pressure line to separate the orifice tube. Loosen orifice tub fitting and separate the pressure line to access the orifice.
2Seal, O-ring Tip: Remove and discard O-ring. Refer to Air Conditioning O-Ring Seal Replacement .
3Orifice Tube Assembly Tip: Use J 26549-E to remove orifice tube. See Special Tools .
CAUTION
Refer to Fastener Caution .

Scheme 18

Scheme 18: Expansion (Orifice) Tube Replacement (W/O C69-HP2)
Scheme 18: Expansion (Orifice) Tube Replacement (W/O C69-HP2)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) . Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1Orifice Tube Fitting CAUTION: Refer to Fastener Caution . Tip: Loosen orifice tub fitting and separate the pressure line to access the orifice. Tighten: 9 N.m (80 lb in)
2O-ring Seal Tip: Remove and discard O-ring. Refer to Air Conditioning O-Ring Seal Replacement .
3Orifice Tube Assembly Tip: Use J 26549-E to remove orifice tube. See Special Tools . Special Tools: J 26549-E Orifice Tube Remover. See Special Tools .
CAUTION
Refer to Fastener Caution .

Scheme 19

Scheme 19: Expansion (Orifice) Tube Replacement (W/C69-HP2)
Scheme 19: Expansion (Orifice) Tube Replacement (W/C69-HP2)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) . Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1Orifice Tube Fitting CAUTION: Refer to Fastener Caution . Tip: It may be necessary to remove the auxiliary pressure line to separate the orifice tube. Loosen orifice tub fitting and separate the pressure line to access the orifice. Tighten: 9 N.m (80 lb in)
2O-ring Seal Tip: Remove and discard O-ring. Refer to Air Conditioning O-Ring Seal Replacement .
3Orifice Tube Assembly Tip: Use to remove orifice tube. Special Tools: J 26549-E Orifice Tube Remover. See Special Tools .
CAUTION
Refer to Fastener Caution .

Scheme 20

Scheme 20: Air Conditioning Cycling Switch Replacement (HP2)
Scheme 20: Air Conditioning Cycling Switch Replacement (HP2)
CalloutComponent Name
Preliminary Procedures: Disconnect the electrical connector from the pressure sensor.
1A/C Refrigerant Pressure Sensor CAUTION: Refer to Fastener Caution . Tip: Remove and discard the O-ring. Refer to Air Conditioning O-Ring Seal Replacement . Tighten: 6 N.m (53 lb in)
CAUTION
Refer to Fastener Caution .
  1. Disconnect the electrical connector from the A/C low pressure switch.
  2. Remove the A/C low pressure switch from the accumulator.
  3. Remove the O-ring and discard.
  1. Install the new O-ring seal to the switch. Refer to «Air Conditioning O-Ring Seal Replacement»(ref-364481-S19153916682010063000000) .
  2. Install the A/C low pressure switch to the accumulator and tighten to 6 N.m (53 lb in).
  3. Connect the electrical connector to the A/C low pressure switch.
  4. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-364481-S11510526782010063000000) .
  1. Disconnect the electrical connector from the A/C refrigerant pressure sensor.
  2. Remove the A/C refrigerant pressure sensor (1) from the condenser tube.
  1. Install the A/C refrigerant pressure sensor (1). Tighten: Tighten the switch to 6 N.m (53 lb in).
  2. Connect the electrical connector to the A/C refrigerant pressure sensor.
  3. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-364481-S11510526782010063000000) .
  4. Lower the vehicle.

Scheme 21

Scheme 21: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (HP2)
Scheme 21: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (HP2)
CalloutComponent Name
Preliminary Procedures Disconnect the electrical connector from the pressure sensor. Remove the upper radiator air baffle.
1A/C Refrigerant Pressure Sensor CAUTION: Refer to Fastener Caution . Tip: Remove and discard the O-ring. Refer to Air Conditioning O-Ring Seal Replacement . Tighten: 6 N.m (53 lb in)
CAUTION
Refer to Fastener Caution .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  2. Remove the fascia.
  3. Remove radiator support bolts (1). Access the bolts from the rear of the upper radiator support. Refer to «Radiator Support Replacement»(ref-364470-S34374486982010063000000) .
  4. Remove radiator support bracket bolts (1).
  5. Remove the compressor discharge hose assembly bolt from the condenser.
  6. Disconnect the compressor discharge hose assembly from the condenser.
  7. Remove the evaporator tube nut from the condenser.
  8. Disconnect the evaporator tube from the condenser.
  9. Remove the insulator retainer bolts and the upper insulator retainers.
  10. Remove the condenser from the vehicle.
  1. Install the condenser to the vehicle.
  2. Install the upper insulator retainers and the insulator retainer bolts and tighten to 2.4 N.m (21 lb in).
  3. Connect the evaporator tube to the condenser using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-364481-S02595102552010063000000) .
  4. Install the evaporator tube nut to the condenser and tighten to 16 N.m (12 lb ft).
  5. Connect the compressor discharge hose to the condenser using new sealing washers. Refer to «Air Conditioning System Seal Replacement»(ref-364481-S02595102552010063000000) .
  6. Install the compressor discharge hose nut to the condenser and tighten to 16 N.m (12 lb ft).
  7. Install the lower bolts to the hood latch support bracket and tighten to 9 N.m (80 lb in).
  8. Install the radiator support. Access the bolts (1) from the rear of the upper radiator support. Refer to «Radiator Support Replacement»(ref-364470-S34374486982010063000000) . Tighten: Tighten the nut to 16 N.m (12 lb ft).
  9. Install radiator support bracket bolts (1).
  10. Install the fascia.
  11. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  12. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-364481-S11510526782010063000000) .

Scheme 22

Scheme 22: Air Conditioning Accumulator Replacement (HP2)
Scheme 22: Air Conditioning Accumulator Replacement (HP2)
CalloutComponent Name
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove the suction hose. Refer to Suction Hose Replacement (W/O C69) or Suction Hose Replacement (W/C69) . Disconnect electrical connector from A/C low pressure switch.
1Accumulator Mounting Bracket Nut CAUTION: Refer to Fastener Caution . Tip: Discard all of the used sealing washers. Tighten: 16 N.m (12 lb in)
2Accumulator Nut Tip: Discard all of the used sealing washers. Tighten: 16 N.m (12 lb in)
3Accumulator Tip: Remove accumulator through wheelhouse opening.
WARNING
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: Identify how to disable high voltage. Identify how to test for the presence of high voltage. Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death.
CAUTION
Refer to Fastener Caution .

Scheme 23

Scheme 23: Air Conditioning Accumulator Replacement (Non-HP2)
Scheme 23: Air Conditioning Accumulator Replacement (Non-HP2)
CalloutComponent Name
Preliminary Procedure: Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) .
1Suction Hose Nut CAUTION: Refer to Fastener Caution . Tip: Large A/C compressor hose to A/C evaporator. Tighten: 16 N.m (12 lb ft)
2A/C Suction Hose
3Sealing Washer Tip: Remove and discard sealing washer. Refer to Air Conditioning System Seal Replacement .
4Accumulator Mounting Bracket Nut Tighten: 16 N.m (12 lb ft)
5Accumulator Nut Tighten: 16 N.m (12 lb ft)
6Sealing Washer Tip: Remove and discard sealing washer. Refer to Air Conditioning System Seal Replacement .
7Accumulator Tip: Replacement service accumulators are shipped dry (no PAG oil). Add proper amount of oil to system before operating. Refer to Refrigerant System Specifications (Non-HP2) .
CAUTION
Refer to Fastener Caution .
  1. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  2. Using the J 43181 disconnect the inlet heater hose from the heater core. See «Special Tools»(ref-364481-S11510526782010063000000) . Install the J 43181 to the heater core pipe. See «Special Tools»(ref-364481-S11510526782010063000000) . Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core.
  3. Using the J 43181 disconnect the surge tank outlet hose from the heater core. See «Special Tools»(ref-364481-S11510526782010063000000) . Install the J 43181 to the heater core pipe. See «Special Tools»(ref-364481-S11510526782010063000000) . Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core.
  4. Remove the upper intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-364523-S11798492912010063000000) .
  5. Remove the battery. Refer to «Battery Replacement»(ref-364485-S28866645562010063000000) .
  6. Remove the accumulator. Refer to «Air Conditioning Accumulator Replacement (Non-HP2)»(ref-364481-S36308378032010063000000) .
  7. Remove the instrument panel to the service position. Refer to «Instrument Panel Service Positioning (With SLT)»(ref-364475-S20841263832010063000000) or «Instrument Panel Service Positioning (Cadillac)»(ref-364475-S11619296422010063000000) .
  8. Remove the HVAC module drain hose.
  9. Disconnect the electrical harnesses and the ground connections from the HVAC module.
  10. Locate the rear engine cover (1) on rear of intake manifold.
  11. Reposition the acoustic foam (if applicable) down from the access location (1).
  12. Remove the nuts (2) from the HVAC module (3).
  13. Remove the bolts (1) from the HVAC module (3).
  14. Remove the HVAC module (3).
  1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary.
  2. Install the HVAC module (3).
  3. Install the nuts (2) to the HVAC module (3) and tighten to 9 N.m (80 lb in).
  4. Install the bolts (1) to the HVAC module (3) and tighten to 4 N.m (35 lb in).
  5. Reposition acoustic foam (if applicable) to original position or cover access hole with equivalent foam tape (1).
  6. Connect the electrical harness and the ground connections.
  7. Install the HVAC module drain hose.
  8. Install the instrument panel. Refer to «Instrument Panel Service Positioning (With SLT)»(ref-364475-S20841263832010063000000) or «Instrument Panel Service Positioning (Cadillac)»(ref-364475-S11619296422010063000000) .
  9. Install the upper intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-364523-S11798492912010063000000) .
  10. Install the battery. Refer to «Battery Replacement»(ref-364485-S28866645562010063000000) .
  11. Install the accumulator. Refer to «Air Conditioning Accumulator Replacement (Non-HP2)»(ref-364481-S36308378032010063000000) .
  12. Install the surge tank outlet hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  13. Install the inlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  14. Fill the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  1. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  2. Using the J 43181 disconnect the inlet heater hose from the heater core. See «Special Tools»(ref-364481-S11510526782010063000000) . Install the J 43181 to the heater core pipe. See «Special Tools»(ref-364481-S11510526782010063000000) . Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core.
  3. Using the J 43181 disconnect the surge tank outlet hose from the heater core. See «Special Tools»(ref-364481-S11510526782010063000000) . Install the J 43181 to the heater core pipe. See «Special Tools»(ref-364481-S11510526782010063000000) . Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core.
  4. Remove the upper intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-364523-S11798492912010063000000) .
  5. Remove the drive motor generator control module assembly. Refer to «Drive Motor Generator Control Module Assembly Replacement»(ref-364527-S05588488292010063000000) .
  6. Remove the battery. Refer to «Battery Replacement»(ref-364485-S28866645562010063000000) .
  7. Remove the accumulator. Refer to «Air Conditioning Accumulator Replacement (HP2)»(ref-364481-S13651537062010063000000) .
  8. Remove the instrument panel to the service position. Refer to «Instrument Panel Service Positioning (With SLT)»(ref-364475-S20841263832010063000000) or «Instrument Panel Service Positioning (Cadillac)»(ref-364475-S11619296422010063000000) .
  9. Remove the HVAC module drain hose.
  10. Disconnect the electrical harnesses and the ground connections from the HVAC module.
  11. Locate the rear engine cover (1) on rear of intake manifold.
  12. Reposition the acoustic foam (if applicable) down from the access location (1).
  13. Remove the nuts (2) from the HVAC module (3).
  14. Remove the bolts (1) from the HVAC module (3).
  15. Remove the HVAC module (3).
  1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary.
  2. Install the HVAC module (3).
  3. Install the nuts (2) to the HVAC module (3) and tighten to 9 N.m (80 lb in).
  4. Install the bolts (1) to the HVAC module (3) and tighten to 4 N.m (35 lb in).
  5. Reposition acoustic foam (if applicable) to original position or cover access hole with equivalent foam tape (1).
  6. Connect the electrical harness and the ground connections.
  7. Install the HVAC module drain hose.
  8. Install the instrument panel. Refer to «Instrument Panel Service Positioning (With SLT)»(ref-364475-S20841263832010063000000) or «Instrument Panel Service Positioning (Cadillac)»(ref-364475-S11619296422010063000000) .
  9. Install the upper intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-364523-S11798492912010063000000) .
  10. Install the drive motor generator control module assembly. Refer to «Drive Motor Generator Control Module Assembly Replacement»(ref-364527-S05588488292010063000000) .
  11. Install the battery. Refer to «Battery Replacement»(ref-364485-S28866645562010063000000) .
  12. Install the accumulator. Refer to «Air Conditioning Accumulator Replacement (HP2)»(ref-364481-S13651537062010063000000) .
  13. Install the surge tank outlet hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  14. Install the inlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  15. Fill the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer.
  3. Disconnect all wiring connections from blower motor, blower motor control module and sensors. Also, remove all wiring from retainers before removal.
  4. If equipped remove the screws from the HVAC module assembly.
  5. Remove the evaporator cowl gasket from the evaporator.
  6. Separate the upper HVAC module assembly (2) from the lower HVAC module assembly (1)
  7. Remove the evaporator core (1) from the upper HVAC module assembly (2).
  8. Remove the air conditioning evaporator air temperature sensor. Refer to «Air Conditioning Refrigerant Temperature Sensor Replacement»(ref-364529-S15205068632010063000000)
  1. Install the evaporator core (1) to the HVAC module assembly (2).
  2. Install the upper HVAC module assembly (2) from the lower HVAC module assembly (1)
  3. Install the evaporator cowl gasket to the evaporator.
  4. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) .
  6. Install the air conditioning evaporator air temperature sensor. Refer to «Air Conditioning Refrigerant Temperature Sensor Replacement»(ref-364529-S15205068632010063000000)
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer.
  3. Disconnect all wiring connections from blower motor, blower motor control module and sensors. Also, remove all wiring from retainers before removal.
  4. If equipped remove the screws from the HVAC module assembly.
  5. Remove the evaporator cowl gasket from the evaporator.
  6. Separate the upper HVAC module assembly (2) from the lower HVAC module assembly (1)
  7. Remove the evaporator core (1) from the upper HVAC module assembly (2).
  1. Install the evaporator core (1) to the HVAC module assembly (2).
  2. Install the upper HVAC module assembly (2) from the lower HVAC module assembly (1)
  3. Install the evaporator cowl gasket to the evaporator.
  4. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  2. Remove the air intake tube.
  3. Remove the heater and surge tank hoses from the mounting clip.
  4. Squeeze the plastic retainer release tabs.
  5. Pull the connection apart.
  6. Remove the inlet heater hose from the water pump.
  7. Remove the inlet heater hose.
  1. Install the inlet heater hose.
  2. Install the inlet heater hose to the water pump.
  3. Connect the heater hose to the heater core.
  4. Install the heater and surge tank hoses to the mounting clip.
  5. Install the air intake tube.
  6. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .

Scheme 24

Scheme 24: Heater Inlet Hose Replacement (Pump to Engine-HP2)
Scheme 24: Heater Inlet Hose Replacement (Pump to Engine-HP2)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement . Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
1Heater Inlet Hose Clamp Procedure: Using J 38185 reposition the radiator surge tank outlet hose clamps. Special Tools: J 38185 Hose Clamp Pliers
2Heater Inlet Hose

Scheme 25

Scheme 25: Heater Inlet Hose Replacement (Pump to Heater Core-HP2)
Scheme 25: Heater Inlet Hose Replacement (Pump to Heater Core-HP2)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement . Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
1Heater Inlet Hose Quick Disconnect Procedure Squeeze the plastic retainer release tabs and pull the connection apart. The joint should audibly click upon reassembly and the technician should pull back on the joint to ensure it's engaged properly.
2Heater Inlet Hose Clamp Procedure: Using J 38185 reposition the radiator surge tank outlet hose clamps. Special Tools: J 38185 Hose Clamp Pliers
3Heater Inlet Hose
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  2. Remove the air intake tube.
  3. Remove the heater and surge tank hoses from the mounting clip.
  4. Squeeze the plastic retainer release tabs.
  5. Pull the connection apart.
  6. Remove the outlet heater hose from the water pump.
  7. Reposition the outlet heater hose clamp at the surge tank.
  8. Remove the outlet heater hose from the surge tank.
  9. Remove the outlet heater hose.
  1. Install the outlet heater hose.
  2. Install the outlet heater hose to the water pump.
  3. Install the outlet heater hose to the surge tank.
  4. Install the outlet heater hose clamp to the surge tank.
  5. Connect the heater and surge tank hoses to the heater core.
  6. Pull the heater outlet hose to ensure the connection.
  7. Install the heater and surge tank hoses to the mounting clip.
  8. Install the air intake tube.
  9. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .

Scheme 26

Scheme 26: Heater Coolant Pump Replacement (HP2)
Scheme 26: Heater Coolant Pump Replacement (HP2)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove the air cleaner resonator duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Disconnect the heater coolant pump electrical connector.
1Heater Coolant Pump Procedure: Using J 38185 reposition the heater hose clamps at pump. Special Tools: J 38185 Hose Clamp Pliers

Scheme 27

Scheme 27: Air Inlet Assembly Replacement
Scheme 27: Air Inlet Assembly Replacement
CalloutComponent Name
Preliminary Procedure Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2) or Air Conditioning and Heater Module Assembly Removal and Installation (HP2) . Disconnect the electrical connector from the recirculation actuator.
1Recirculation Actuator Screw (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2Recirculation Actuator
3Air Inlet Assembly Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
4Air Inlet Assembly Tip: Tilt the rear of the air inlet assembly upward to release front mounting tabs.
CAUTION
Refer to Fastener Caution .

Scheme 28

Scheme 28: Blower Motor Control Module Replacement
Scheme 28: Blower Motor Control Module Replacement
CalloutComponent Name
Preliminary Procedure Remove the I/P insulator panel. Refer to Instrument Panel Insulator Replacement (Cadillac) or Instrument Panel Insulator Replacement (Except Cadillac) . Disconnect the blower motor control module electrical connector.
1Blower Motor Control Module Screw (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2Blower Motor Control Module
CAUTION
Refer to Fastener Caution .
  1. If equipped, remove the sound insulator panel. Refer to «Instrument Panel Insulator Replacement (Cadillac)»(ref-364475-S18078497542010063000000) or «Instrument Panel Insulator Replacement (Except Cadillac)»(ref-364475-S28915926132010063000000) .
  2. Remove the blower motor insulating cover screws.
  3. Disconnect the electrical connector from the blower motor.
  4. Remove the blower motor insulating cover.
  5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module.
  6. Remove the blower motor.
  1. Install the blower motor.
  2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place.
  3. Install the blower motor insulating cover.
  4. Connect the electrical connector to the blower motor.
  5. Install the blower motor insulating cover screws and tighten to 1.6 N.m (14 lb in).
  6. If equipped, install the sound insulator panel. Refer to «Instrument Panel Insulator Replacement (Cadillac)»(ref-364475-S18078497542010063000000) or «Instrument Panel Insulator Replacement (Except Cadillac)»(ref-364475-S28915926132010063000000) .

Scheme 29

Scheme 29: Air Distributor Duct Replacement
Scheme 29: Air Distributor Duct Replacement
CalloutComponent Name
Preliminary Procedure: Remove the instrument panel to the service position. Refer to Instrument Panel Service Positioning (With SLT) or Instrument Panel Service Positioning (Cadillac) .
1Air Distributor Bolts and Rivets (Qty: 6) CAUTION: Refer to Fastener Caution . Tighten: 2.5 N.m (16 lb in)
2Air Distributor Duct
CAUTION
Refer to Fastener Caution .

Scheme 30

Scheme 30: Instrument Panel Outer Air Outlet Deflector Replacement - Left Side (Except Cadillac)
Scheme 30: Instrument Panel Outer Air Outlet Deflector Replacement - Left Side (Except Cadillac)
CalloutComponent Name
1Instrument Panel Air Deflector - Left Tip: Use a flat-bladed plastic trim tool to release the retainer clip on the right side of the deflector, securing the air deflector to the instrument panel.
2Retainer Clip (Qty: 1)

Scheme 31

Scheme 31: Instrument Panel Outer Air Outlet Deflector Replacement - Left Side (Cadillac)
Scheme 31: Instrument Panel Outer Air Outlet Deflector Replacement - Left Side (Cadillac)
CalloutComponent Name
1Instrument Panel Air Deflector - Left Tip: Use a flat-bladed plastic trim tool to release the retainer clips on the right side of the deflector, securing the air deflector to the instrument panel.
2Retainer Clip (Qty: 2)

Scheme 32

Scheme 32: Instrument Panel Center Air Outlet Deflector Replacement (Cadillac)
Scheme 32: Instrument Panel Center Air Outlet Deflector Replacement (Cadillac)
CalloutComponent Name
1Instrument Panel Accessory Trim Panel Refer to Instrument Panel Accessory Trim Plate Replacement (Cadillac) .
2Instrument Panel Center Air Deflector - Left Tip: Release the tabs securing the air deflector to the trim panel.
3Instrument Panel Center Air Deflector - Right Tip: Release the tabs securing the air deflector to the trim panel.

Scheme 33

Scheme 33: Instrument Panel Center Air Outlet Deflector Replacement (Except Cadillac)
Scheme 33: Instrument Panel Center Air Outlet Deflector Replacement (Except Cadillac)
CalloutComponent Name
1Instrument Panel Center Trim Panel Refer to Instrument Panel Center Trim Panel Replacement (Except Cadillac) .
2Instrument Panel Center Air Deflector - Left Tip: Release the tabs securing the air deflector to the trim panel.
3Instrument Panel Center Air Deflector - Right Tip: Release the tabs securing the air deflector to the trim panel.

Scheme 34

Scheme 34: Instrument Panel Outer Air Outlet Deflector Replacement - Right Side (Cadillac)
Scheme 34: Instrument Panel Outer Air Outlet Deflector Replacement - Right Side (Cadillac)
CalloutComponent Name
1Instrument Panel Center Trim Panel Refer to Instrument Panel Center Trim Panel Replacement (Cadillac) .
2Instrument Panel Right Air Deflector Tip: Release the tabs securing the air deflector to the trim panel.

Scheme 35

Scheme 35: Instrument Panel Outer Air Outlet Deflector Replacement - Right Side (Except Cadillac)
Scheme 35: Instrument Panel Outer Air Outlet Deflector Replacement - Right Side (Except Cadillac)
CalloutComponent Name
Preliminary Procedure: Remove the instrument panel center trim panel. Refer to Instrument Panel Center Trim Panel Replacement (Except Cadillac) .
1Instrument Panel Air Deflector Screw (Qty: 1) CAUTION: Refer to Fastener Caution . Tighten: 2 N.m (18 lb in)
2Instrument Panel Air Deflector - Right Tip: Use a flat-bladed plastic trim tool to release the retainer clip on the left side of the deflector, securing the air deflector to the instrument panel.
3Retainer Clip (Qty: 1)
CAUTION
Refer to Fastener Caution .

Scheme 36

Scheme 36: Floor Console Auxiliary Air Outlet Replacement
Scheme 36: Floor Console Auxiliary Air Outlet Replacement
CalloutComponent Name
1Front Floor Console Compartment Bezel Refer to Front Floor Console Compartment Bezel Replacement (Except Cadillac) or Front Floor Console Compartment Bezel Replacement (Cadillac) .
2Front Floor Console Rear Air Deflector - Left
3Front Floor Console Rear Air Deflector - Right
  1. Remove the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  2. Roll the carpeting back to expose the rear floor air ducts.
  3. Remove the rear floor ducts from the floor studs.
  4. 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 assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  1. Remove the push pin from the left floor air outlet duct (3).
  2. Remove the left floor duct (3) from the right floor air outlet duct (2).
  1. Install the left floor air outlet duct (3) to the right floor air outlet duct (2).
  2. Install the push pin to the left floor air outlet duct (3).

Scheme 37

Scheme 37: Floor Air Outlet Duct Replacement - Right Side
Scheme 37: Floor Air Outlet Duct Replacement - Right Side
CalloutComponent Name
Preliminary Procedure Remove the I/P insulator. Refer to Instrument Panel Insulator Replacement (Cadillac) or Instrument Panel Insulator Replacement (Except Cadillac) . Remove the front floor console side trim panel - right. Refer to Front Floor Console Side Trim Panel Replacement - Right Side (Cadillac) or Front Floor Console Side Trim Panel Replacement - Right Side (Except Cadillac) .
1Air Duct Bolt CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2Air Outlet Duct - Floor RH Tip: Slide Duct to the right and remove.
CAUTION
Refer to Fastener Caution .
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screwdriver and a hammer.
  3. If equipped remove the HVAC module assembly screws.
  4. Remove the upper HVAC module case (1) from the lower HVAC module case (2).
  5. Remove the right temperature door (4) from the upper HVAC module case (3).
  1. Install the right temperature door (4) to the upper HVAC module case (3).
  2. Install the upper HVAC module case (1) to the lower HVAC module case (2).
  3. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  4. Install the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer.
  3. If equipped remove the HVAC module assembly screws.
  4. Remove the upper HVAC module case (3) from the lower HVAC module case (10).
  5. Remove the air temperature separator plate (5) from the lower HVAC module case (10).
  6. Remove the left temperature door (11) from the lower HVAC module case (10).
  1. Install the left temperature door (11) to the lower HVAC module case (10).
  2. Install the air temperature separator plate (5) to the lower HVAC module case (10).
  3. Install the upper HVAC module case (3) to the lower HVAC module case (10).
  4. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  5. Install the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screwdriver and a hammer.
  3. If equipped remove the HVAC module assembly screws.
  4. Separate the HVAC module assembly.
  5. Remove the mode actuator screws.
  6. Remove the mode actuator.
  7. Remove the mode actuator cam assembly.
  8. Remove the defroster door (8).
  1. Install the defroster door (8).
  2. Install the mode actuator cam assembly.
  3. Install the mode actuator.
  4. Install the mode actuator screws and tighten to 1.6 N.m (14 lb in).
  5. Install the HVAC module assembly halves.
  6. Install the screws to the HVAC module assembly and tighten to 1.6 N.m (14 lb in).
  7. Install the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screwdriver and a hammer.
  3. If equipped remove the HVAC module assembly screws.
  4. Separate the HVAC module assembly.
  5. Remove the air temperature separator plate (5) from the HVAC module assembly (10).
  6. Remove the lower mode door (9) from the HVAC module assembly (10).
  1. Install the lower mode door (9) to the HVAC module assembly (10).
  2. Install the air temperature separator plate (5) to the HVAC module assembly (10).
  3. Install the HVAC module assembly halves.
  4. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  5. Install the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .

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

  1. Remove the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .
  2. Disconnect the electrical connector from the mode actuator.
  3. Remove the screws from the mode actuator.
  4. Remove the mode actuator from the HVAC module assembly (1).
  5. If equipped remove the heat stakes (1) from the HVAC module (2) with a screwdriver and a hammer.
  6. If equipped remove the HVAC module assembly screws.
  7. Separate the HVAC module assembly.
  8. Remove the lever (7) from the upper mode door/upper HVAC module case (6).
  1. Install the lever (7) to the upper mode door/upper HVAC module case (6).
  2. Install the HVAC module assembly halves.
  3. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  4. Install the mode actuator to the HVAC module assembly.
  5. Install the screws to the mode actuator. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  6. Connect the electrical connector to the mode actuator.
  7. Install the HVAC module. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2)»(ref-364481-S07685162802010063000000) or «Air Conditioning and Heater Module Assembly Removal and Installation (HP2)»(ref-364481-S22279262222010063000000) .

Scheme 38

Scheme 38: Heater Core Cover Replacement
Scheme 38: Heater Core Cover Replacement
CalloutComponent Name
Preliminary Procedure: Remove the HVAC module. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2) or Air Conditioning and Heater Module Assembly Removal and Installation (HP2) .
1Heater Core Cover Screw CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2Heater Core Cover
CAUTION
Refer to Fastener Caution .

Scheme 39

Scheme 39: Heater Core Replacement
Scheme 39: Heater Core Replacement
CalloutComponent Name
Preliminary Procedure Remove the HVAC module. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (Non-HP2) or Air Conditioning and Heater Module Assembly Removal and Installation (HP2) . Disconnect the wiring harness retainer from the heater core cover.
1Heater Core Cover Screw CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (14 lb in)
2Heater Core Cover Tighten: 1.5 N.m (14 lb in)
3Heater Core Pass Through Seal
4Heater Core
CAUTION
Refer to Fastener Caution .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  2. Before removing the quick connect fitting from the vehicle, clean area and remove any loose dirt or debris.
  3. Remove the fitting from the tube by squeezing the retainer clip legs together and pulling the fitting from the tube.
  4. Remove the retainer from the tube by folding the legs back on themselves and sliding the retainer clip out of the tube (1).
  5. Place a flat-blade tool through the window of the quick connect fitting to just below the outer bushing and above the top O-ring (2).
  6. Remove the outer bushing with a gentle prying motion. Discard the outer bushing.
  7. Remove other components and discard.
  8. Thoroughly clean and inspect the inside surface of the fitting for nicks, scratches or cracks. Remove any dirt or debris using water and a lint free cloth.
  1. Lubricate O-rings with coolant.
  2. Install the first O-ring and gently push down into the O-ring pocket (4).
  3. Install the midspacer and gently push down to first O-ring (3).
  4. Install the second O-ring and gently push down to the top of midspacer (2).
  5. Install the retainer clip by lining up the retainer legs with windows on the fitting housing (1). Push the retainer clip down until the retainer clip legs are engaged into the windows.
  6. Clean and inspect the pipe end for any nicks, scratches or cracks.
  7. Install the fitting to the vehicle by pushing the fitting onto the tube until an audible click is heard. Pull back to verify the connection is secure.
  8. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  2. Squeeze the plastic retainer tabs on the inlet hose.
  3. Pull the connection apart.
  4. Squeeze the plastic retainer tabs on the outlet hose.
  5. Pull the connection apart.
  6. Remove the auxiliary heater pipes (1, 2) from the heater inlet and outlet tees (3, 4) at the HVAC module.
  7. Remove the vehicle right assist step. Refer to «Assist Step Replacement (Z71)»(ref-364494-S27589204062010063000000) or «Assist Step Replacement (Power BRS)»(ref-364494-S37025046262010063000000) or «Assist Step Replacement (Chevrolet HP2)»(ref-364494-S27742095842010063000000) or «Assist Step Replacement (GMC Denali XL)»(ref-364494-S01131970862010063000000) . Remove both of the right tires. Refer to «Tire and Wheel Removal and Installation»(ref-364499-S02143103562010063000000) .
  8. Remove the right rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement (RPO HP2)»(ref-364494-S40867080842010063000000) or «Rear Wheelhouse Panel Liner Replacement (RPO X88 Chevrolet, RPO O88 GMC)»(ref-364494-S06898559732010063000000) .
  9. Remove the right front wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Right Side»(ref-364494-S25086668132010063000000) .
  10. Remove the auxiliary heater pipes (2, 3) from the auxiliary heater core.
  11. Remove the heater/A/C tubes retaining nut (4) from the stud (1) at the frame (6).
  12. Remove the auxiliary heater pipes (2) from the clamps (5).
  13. Remove the auxiliary heater pipes from the vehicle.

Note. The replacement A/C and heater pipes are shipped in two sections and spliced together upon installation. Refer to Auxiliary Heater and Air Conditioning Pipe Repair .

  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) and tighten to 7 N.m (62 lb in).
  4. Install the auxiliary heater pipes (2, 3) to the auxiliary heater core.
  5. Install the right front wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Right Side»(ref-364494-S25086668132010063000000) .
  6. Install the right rear wheelhouse panel. Refer to «Rear Wheelhouse Panel Liner Replacement (RPO HP2)»(ref-364494-S40867080842010063000000) or «Rear Wheelhouse Panel Liner Replacement (RPO X88 Chevrolet, RPO O88 GMC)»(ref-364494-S06898559732010063000000) .
  7. Install the vehicle right assist step. Refer to «Assist Step Replacement (Z71)»(ref-364494-S27589204062010063000000) or «Assist Step Replacement (Power BRS)»(ref-364494-S37025046262010063000000) or «Assist Step Replacement (Chevrolet HP2)»(ref-364494-S27742095842010063000000) or «Assist Step Replacement (GMC Denali XL)»(ref-364494-S01131970862010063000000) .
  8. Install the auxiliary heater pipes (1, 2) to the heater inlet and outlet tees (3, 4).
  9. Connect the outlet heater hose to the heater core.
  10. Connect the inlet heater hose to the heater core.
  11. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .

Scheme 40

Scheme 40: Auxiliary Blower Control Module Replacement
Scheme 40: Auxiliary Blower Control Module Replacement
CalloutComponent Name
Preliminary Procedure Remove the right rear quarter trim panel. Refer to Rear Quarter Trim Panel Replacement - Right Side (Standard Wheelbase) or Rear Quarter Trim Panel Replacement - Right Side (Extended Wheelbase) . Disconnect the blower motor control module electrical connector.
1Screw, Blower Motor Resistor (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2Module, Blower Motor Control
CAUTION
Refer to Fastener Caution .

Scheme 41

Scheme 41: Auxiliary Blower Motor Replacement (Standard Wheelbase)
Scheme 41: Auxiliary Blower Motor Replacement (Standard Wheelbase)
CalloutComponent Name
Preliminary Procedure Remove the right rear quarter trim panel. Refer to Rear Quarter Trim Panel Replacement - Right Side (Standard Wheelbase) or Rear Quarter Trim Panel Replacement - Right Side (Extended Wheelbase) . Disconnect the blower motor electrical connector.
1Locking Tab (Qty: 2) Procedure Remove one attaching screw securing blower motor if applicable Carefully pull back locking tabs on blower motor assembly.
2Auxiliary Blower Motor Assembly Procedure: Rotate blower motor counterclockwise to remove.

Scheme 42

Scheme 42: Auxiliary Blower Motor Replacement (Extended Wheelbase)
Scheme 42: Auxiliary Blower Motor Replacement (Extended Wheelbase)
CalloutComponent Name
Preliminary Procedure Remove the right rear quarter trim panel. Refer to Rear Quarter Trim Panel Replacement - Right Side (Standard Wheelbase) or Rear Quarter Trim Panel Replacement - Right Side (Extended Wheelbase) . Disconnect the blower motor electrical connector.
1Blower Motor Screw (Qty: 3) CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2Blower Motor Assembly
CAUTION
Refer to Fastener Caution .

Scheme 43

Scheme 43: Auxiliary Air Distributor Duct Replacement (Lower/Extended Wheelbase)
Scheme 43: Auxiliary Air Distributor Duct Replacement (Lower/Extended Wheelbase)
CalloutComponent Name
Preliminary Procedures Remove the right rear quarter trim panel. Refer to Rear Quarter Trim Panel Replacement - Right Side (Standard Wheelbase) or Rear Quarter Trim Panel Replacement - Right Side (Extended Wheelbase) . Remove the air temperature sensor, if equipped. Duct has one screw holding it on, in the inside of duct must be removed.
1Air Duct, Lower Tip: Small hidden screw inside duct. Squeeze the inside edge of the lower duct until the edge is clear of the air distributor duct.

Scheme 44

Scheme 44: Auxiliary Air Distributor Duct Replacement (Upper/Extended Wheelbase)
Scheme 44: Auxiliary Air Distributor Duct Replacement (Upper/Extended Wheelbase)
CalloutComponent Name
Preliminary Procedures Remove the right rear quarter trim panel. Refer to Rear Quarter Trim Panel Replacement - Right Side (Standard Wheelbase) or Rear Quarter Trim Panel Replacement - Right Side (Extended Wheelbase) . Remove the upper air temperature sensor, if equipped.
1Screw, Air Duct Upper (Qty: 1) CAUTION: Refer to Fastener Caution . Tip: Release retainer on body side of duct Tighten: 1.5 N.m (13 lb in)
2Air Duct, Upper Tip: Carefully slide the duct up to the headliner, until the bottom edge of the duct is above the air distributor duct.
CAUTION
Refer to Fastener Caution .

Scheme 45

Scheme 45: Auxiliary Heater Core Replacement (Extended Wheelbase)
Scheme 45: Auxiliary Heater Core Replacement (Extended Wheelbase)
CalloutComponent Name
Preliminary Procedure Remove the HVAC module - auxiliary. Refer to Auxiliary HVAC Module Removal and Installation (Standard Wheelbase) or Auxiliary HVAC Module Removal and Installation (Extended Wheelbase) . Disconnect any wiring connectors or harnesses from HVAC module.
1Auxiliary HVAC Module Lower Cover Bolt (Qty: 4) CAUTION: Refer to Fastener Caution . Tip: Remove any fastener clips that secure cover to module. Tighten: 9 N.m (80 lb in)
2Auxiliary HVAC Module Lower Cover
3Auxiliary HVAC Heater Core Tip: Ensure all seals and gaskets are in place upon installation.
CAUTION
Refer to Fastener Caution .

Scheme 46

Scheme 46: Auxiliary Heater Core Replacement (Standard Wheelbase)
Scheme 46: Auxiliary Heater Core Replacement (Standard Wheelbase)
CalloutComponent Name
Preliminary Procedure Remove the HVAC module - auxiliary. Refer to Auxiliary HVAC Module Removal and Installation (Standard Wheelbase) or Auxiliary HVAC Module Removal and Installation (Extended Wheelbase) . Disconnect any wiring connectors or harnesses from HVAC module.
1HVAC Module Gasket
2Auxiliary HVAC Module Lower Cover Bolt (Qty: 3) CAUTION: Refer to Fastener Caution . Tip: Remove any fastener clips that secure cover to module. Tighten: 3 N.m (27 lb in)
3Auxiliary HVAC Module Lower Cover
4Separate the HVAC Module Case Tip: Remove any fastener clips that secure cover to module. Tighten: 3 N.m (27 lb in)
5Auxiliary HVAC Heater Core Tip: Ensure all seals and gaskets are in place upon installation.
CAUTION
Refer to Fastener Caution .

Scheme 47

Scheme 47: Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement
Scheme 47: Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) or Refrigerant Recovery and Recharging (Non-HP2) . Remove the retaining nut and the auxiliary A/C evaporator tubes from the auxiliary HVAC module. Refer to Auxiliary Air Conditioning Evaporator Tube Replacement .
1Thermal Expansion Valve Bolt (Qty: 2) CAUTION: Refer to Fastener Caution . Tip: Insert a small phillips screwdriver through one of the thermal expansion valve (TXV) bolt holes and into the threaded hole of the mounting plate. Install the TXV bolt into the other hole without the screwdriver. Remove the screwdriver and install the other TXV bolt. Tighten: 5 N.m (44 lb in)
2Sealing Washer Tip: Remove and discard the sealing washer. Refer to Air Conditioning System Seal Replacement .
3Thermal Expansion Valve Procedure: The auxiliary A/C refrigerant filter must be replaced when the auxiliary thermal expansion valve is serviced. Refer to Air Conditioning (AC) Refrigerant Filter Replacement (C69) or Air Conditioning (AC) Refrigerant Filter Replacement (C69-HP2) .
CAUTION
Refer to Fastener Caution .
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging (HP2)»(ref-364481-S08730334532010063000000) or «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  2. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-364496-S07186948972010063000000) .
  4. Disconnect the heater lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle.
  5. Disconnect the air conditioning lines (4, 5) from the auxiliary HVAC module at the underside of the vehicle.
  6. Remove the nuts (6) from the studs (1) that secure the auxiliary HVAC module to the underside of the vehicle.
  7. Lower the vehicle.
  8. Remove the right rear quarter trim panel. Refer to «Rear Quarter Trim Panel Replacement - Right Side (Standard Wheelbase)»(ref-364472-S23804380902010063000000) or «Rear Quarter Trim Panel Replacement - Right Side (Extended Wheelbase)»(ref-364472-S05668130422010063000000) .
  9. Disconnect the electrical connectors from the Auxiliary HVAC module.
  10. 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.
  11. Remove the fasteners (3) retaining the auxiliary HVAC module to the vehicle.
  12. Remove the auxiliary HVAC module (4) from the vehicle.
  1. Install the auxiliary HVAC module assembly (4) to the vehicle.
  2. Install the 2 bolts (3) inside the vehicle in order to retain the auxiliary HVAC module to the vehicle.
  3. Install the upper auxiliary air duct (1) to the air distributor duct. Install the fastener (5).
  4. Connect the electrical connectors to the auxiliary HVAC module.
  5. Install the right rear quarter trim panel. Refer to «Rear Quarter Trim Panel Replacement - Right Side (Standard Wheelbase)»(ref-364472-S23804380902010063000000) or «Rear Quarter Trim Panel Replacement - Right Side (Extended Wheelbase)»(ref-364472-S05668130422010063000000) .
  6. Raise the vehicle.
  7. Install the nuts (6) that secure the auxiliary HVAC module to the vehicle and tighten to 9 N.m (80 lb in).
  8. Install the air conditioning lines (4, 5) and the nut (4) to the auxiliary HVAC module and tighten to 16 N.m (12 lb ft).
  9. Install the heater lines (2, 3) to the auxiliary HVAC module at the underside of vehicle.
  10. Lower the vehicle.
  11. Fill the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  12. Recharge the refrigerant to the system. Refer to «Refrigerant Recovery and Recharging (HP2)»(ref-364481-S08730334532010063000000) or «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  13. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-364481-S11510526782010063000000) .
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging (HP2)»(ref-364481-S08730334532010063000000) or «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  2. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-364496-S07186948972010063000000) .
  4. Disconnect the heater lines (2, 3) from the auxiliary HVAC module at the underside of the vehicle.
  5. Disconnect the air conditioning lines (4, 5) from the auxiliary HVAC module at the underside of the vehicle.
  6. Remove the nuts (6) from the studs (1) that secure the auxiliary HVAC module to the underside of the vehicle.
  7. Lower the vehicle.
  8. Remove the right rear quarter trim panel. Refer to «Rear Quarter Trim Panel Replacement - Right Side (Standard Wheelbase)»(ref-364472-S23804380902010063000000) or «Rear Quarter Trim Panel Replacement - Right Side (Extended Wheelbase)»(ref-364472-S05668130422010063000000) .
  9. Disconnect the electrical connectors from the auxiliary HVAC module.
  10. Remove the forward auxiliary air duct from HVAC module.
  11. Remove the fasteners (1) retaining the auxiliary HVAC module to the vehicle.
  12. Remove the auxiliary HVAC module (2) from the vehicle.
  1. Install the auxiliary HVAC module assembly (2) to the vehicle.
  2. Install the 2 bolts (1) inside the vehicle in order to retain the auxiliary HVAC module to the vehicle.
  3. Install the forward auxiliary air duct.
  4. Connect the electrical connectors to the auxiliary HVAC module.
  5. Install the right rear quarter trim panel. Refer to «Rear Quarter Trim Panel Replacement - Right Side (Standard Wheelbase)»(ref-364472-S23804380902010063000000) or «Rear Quarter Trim Panel Replacement - Right Side (Extended Wheelbase)»(ref-364472-S05668130422010063000000) .
  6. Raise the vehicle.
  7. Install the nuts (6) that secure the auxiliary HVAC module to the vehicle and tighten to 9 N.m (80 lb in).
  8. Install the air conditioning lines (4, 5) and the nut to the auxiliary HVAC module and tighten to 16 N.m (12 lb ft).
  9. Install the heater lines (2, 3) to the auxiliary HVAC module at the underside of vehicle.
  10. Lower the vehicle.
  11. Fill the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  12. Recharge the refrigerant to the system. Refer to «Refrigerant Recovery and Recharging (HP2)»(ref-364481-S08730334532010063000000) or «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  13. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-364481-S11510526782010063000000) .

Scheme 48

Scheme 48: Auxiliary Air Conditioning Evaporator Replacement (Standard Wheelbase)
Scheme 48: Auxiliary Air Conditioning Evaporator Replacement (Standard Wheelbase)
CalloutComponent Name
Preliminary Procedure Remove the HVAC module - auxiliary. Refer to Auxiliary HVAC Module Removal and Installation (Standard Wheelbase) or Auxiliary HVAC Module Removal and Installation (Extended Wheelbase) . Disconnect any wiring connectors or harnesses from HVAC module.
1HVAC Module Gasket
2Auxiliary HVAC Module Lower Cover Bolt (Qty: 3) CAUTION: Refer to Fastener Caution . Procedure: Remove any fastener clips that secure cover to module. Tighten: 3 N.m (27 lb in)
3Auxiliary HVAC Module Lower Cover
4HVAC Module Case Procedure: Remove any fastener clips that secure cover to module. Tighten: 3 N.m (27 lb in)
5Auxiliary HVAC Evaporator Core Procedure: Ensure all seals and gaskets are in place upon installation.
CAUTION
Refer to Fastener Caution .

Scheme 49

Scheme 49: Auxiliary Air Conditioning Evaporator Replacement (Extended Wheelbase)
Scheme 49: Auxiliary Air Conditioning Evaporator Replacement (Extended Wheelbase)
CalloutComponent Name
Preliminary Procedure Remove the HVAC module - auxiliary. Refer to Auxiliary HVAC Module Removal and Installation (Standard Wheelbase) or Auxiliary HVAC Module Removal and Installation (Extended Wheelbase) . Remove the thermal expansion valve (TXV) - auxilliary. Refer to Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement . Disconnect any wiring connectors or harnesses from the HVAC module.
1Auxiliary HVAC Module Lower Cover Bolt (Qty: 4) CAUTION: Refer to Fastener Caution . Tip: Remove any fastener clips that secure cover to module. Tighten: 9 N.m (80 lb in)
2Auxiliary HVAC Module Lower Cover
3Auxiliary HVAC Evaporator Tip: Ensure all seals and gaskets are in place upon installation.
CAUTION
Refer to Fastener Caution .
  1. Recover the refrigerant from the system. Refer to «Refrigerant Recovery and Recharging (HP2)»(ref-364481-S08730334532010063000000) or «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  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. Refer to «Lifting and Jacking the Vehicle»(ref-364496-S07186948972010063000000) .
  5. Remove the right assist step. Refer to «Assist Step Replacement (Z71)»(ref-364494-S27589204062010063000000) or «Assist Step Replacement (Power BRS)»(ref-364494-S37025046262010063000000) or «Assist Step Replacement (Chevrolet HP2)»(ref-364494-S27742095842010063000000) or «Assist Step Replacement (GMC Denali XL)»(ref-364494-S01131970862010063000000) .
  6. Remove the front wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side»(ref-364494-S25086668132010063000000) .
  7. Remove the rear wheelhouse liner. Refer to «Rear Wheelhouse Panel Liner Replacement (RPO HP2)»(ref-364494-S40867080842010063000000) or «Rear Wheelhouse Panel Liner Replacement (RPO X88 Chevrolet, RPO O88 GMC)»(ref-364494-S06898559732010063000000) .
  8. Remove the retaining nut (2) and the auxiliary A/C evaporator tubes (3) from the auxiliary HVAC module.
  9. Remove the heater/A/C tubes retaining nut (4) from the stud (1) at the frame (6).
  10. Remove the auxiliary A/C evaporator tubes (3) from the clamps (5).
  11. Remove the auxiliary A/C evaporator tubes from the vehicle.

Note. The replacement A/C and heater pipes are shipped in two sections and spliced together upon installation. Refer to Auxiliary Heater and Air Conditioning Pipe Repair .

  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) and tighten 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 and tighten to 16 N.m (12 lb ft).
  5. Lower the vehicle.
  6. Install the rear wheelhouse liner. Refer to «Rear Wheelhouse Panel Liner Replacement (RPO HP2)»(ref-364494-S40867080842010063000000) or «Rear Wheelhouse Panel Liner Replacement (RPO X88 Chevrolet, RPO O88 GMC)»(ref-364494-S06898559732010063000000) .
  7. Install the right assist step. Refer to «Assist Step Replacement (Z71)»(ref-364494-S27589204062010063000000) or «Assist Step Replacement (Power BRS)»(ref-364494-S37025046262010063000000) or «Assist Step Replacement (Chevrolet HP2)»(ref-364494-S27742095842010063000000) or «Assist Step Replacement (GMC Denali XL)»(ref-364494-S01131970862010063000000) .
  8. Install the front wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side»(ref-364494-S25086668132010063000000) .
  9. Install the auxiliary A/C evaporator tubes (3) to the condenser tube (2) and the accumulator (5) using the nuts and tighten to 16 N.m (12 lb ft).
  10. Recharge the refrigerant to the system. Refer to «Refrigerant Recovery and Recharging (HP2)»(ref-364481-S08730334532010063000000) or «Refrigerant Recovery and Recharging (Non-HP2)»(ref-364481-S37774139622010063000000) .
  11. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-364481-S11510526782010063000000) .

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