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Heating, Ventilation and Air Conditioning: Removal & Installation Hummer H2 I

Automatic HVAC System 1 illustration ~6077 words

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  2. Remove the fan shroud. Refer to «Fan Shroud Replacement»(ref-187257-S17735825252005083100000) in Engine Cooling.
  3. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
  4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
  5. Remove the A/C belt from the A/C compressor.
  6. Slowly release the tension on the A/C belt tensioner.
  7. Remove the A/C discharge hose bolt from the A/C compressor.
  8. Remove the A/C discharge hose from the A/C compressor.
  9. Remove the A/C suction hose bolt from the A/C compressor.
  10. Remove the A/C suction hose from the A/C compressor.
  11. Discard the sealing washers.
  12. Cap or tape all of the hose and line ends.
  13. Disconnect the electrical connector from the A/C compressor coil.
  14. Remove the A/C compressor mounting bolts.
  15. Remove the A/C compressor (2) from the bracket (1).
  16. If replacing the A/C compressor. Refer to «Compressor Oil Balancing»(ref-187267-S06238286102005083100000) .

Installation Procedure

  1. Add the proper amount of PAG oil to the compressor crankcase. Refer to «Refrigerant System Capacities»(ref-187267-S27339359592005083100000) .
  2. Install the A/C compressor (2) to the bracket (1).
  3. Install the A/C compressor mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  4. Connect the electrical connector to the A/C compressor coil.
  5. Remove the caps or tape from the hose and line ends.
  6. Install the new sealing washers. Refer to «Sealing Washer Replacement»(ref-187267-S32968695222005083100000) .
  7. Install the A/C suction hose to the compressor.
  8. Install the A/C suction hose bolt to the A/C compressor. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  9. Install the A/C discharge hose to the A/C compressor.
  10. Install the A/C discharge hose bolt to the A/C compressor. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  11. Install the A/C drive belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-187255-S19335454772005083100000) in Engine Mechanical - 6.0L.
  12. Install the fan shroud. Refer to «Fan Shroud Replacement»(ref-187257-S17735825252005083100000) in Engine Cooling.
  13. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  14. Leak test the fittings of the component using the J 39400-A . See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  2. Remove the bolts from the engine protection shield.
  3. Remove the engine protection shield.
  4. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
  5. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
  6. Remove the A/C belt from the A/C compressor.
  7. Slowly release the tension on the A/C belt tensioner.
  8. Remove the clutch plate retaining bolt (1).
  9. Remove the clutch plate assembly (2).
  10. Remove the clutch hub/bearing snap ring (3).
  11. Remove the clutch hub/bearing assembly (4).
  12. Remove the snap ring (5) from the clutch coil (6).
  13. Remove the clutch coil (6) from the A/C compressor (7).
  1. Install the clutch coil (6) to the A/C compressor (7).
  2. Install the snap ring (5) to the clutch coil (6).
  3. Install the clutch hub/bearing assembly (4).
  4. Install the clutch hub/bearing snap ring (3).
  5. Install the clutch plate assembly (2).
  6. Install the clutch plate retaining bolt (1). Tighten: Tighten the bolt to 18 N.m (13 lb ft).
  7. Install a ratchet into the A/C belt tensioner adapter opening.
  8. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
  9. Install the A/C belt to the A/C compressor.
  10. Slowly release the tension on the A/C belt tensioner.
  11. Remove the ratchet from the A/C belt tensioner.
  12. Install the engine protection shield.
  13. Install the bolts to the engine protection shield. Tighten: Tighten the bolt to 30 N.m (22 lb ft).
  14. Lower the vehicle.
  1. Remove the A/C compressor. Refer to «Compressor Replacement»(ref-187267-S26052716162005083100000) .
  2. Remove the A/C belt tensioner bolts.
  3. Remove the A/C belt tensioner.
  4. Remove the A/C compressor bracket mounting bolts.
  5. Remove the A/C compressor bracket.
  1. Install the A/C compressor bracket.
  2. Install the A/C compressor bracket mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  3. Install the A/C belt tensioner.
  4. Install the A/C belt tensioner bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  5. Install the A/C compressor. Refer to «Compressor Replacement»(ref-187267-S26052716162005083100000) .
  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»(ref-187267-S22246222552005083100000) .
  2. Disconnect the electrical connector from the A/C recirculation switch.
  3. Remove the A/C recirculation switch from the A/C discharge hose.
  4. Remove the discharge hose bolt (6) from the A/C compressor (4).
  5. Remove the discharge hose (5) from the A/C compressor (4).
  6. Remove the discharge hose nut (1) from the condenser (2).
  7. Remove the discharge hose (3) from the condenser (2).
  8. Remove the discharge hose (3) from the vehicle.
  9. Discard all of the used sealing washers.
  10. Cap all of the A/C system openings.
  1. Install the new sealing washers. Refer to «Sealing Washer Replacement»(ref-187267-S32968695222005083100000)
  2. Install the discharge hose (3) to the vehicle.
  3. Install the discharge hose (3) to the condenser (2).
  4. Install the nut (1) to the condenser (2). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install the discharge hose (5) to the A/C compressor (4).
  6. Install the discharge hose bolt (6) to the A/C compressor (4). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  7. Install the A/C recirculation switch to the discharge hose (5).
  8. Connect the electrical connector to the A/C recirculation switch.
  9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  10. Leak test the fittings of the component using the J 39400-A . See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  2. Remove the suction hose mounting bolt (2) from the A/C compressor (4).
  3. Remove the suction hose (1) from the A/C compressor (4).
  4. Remove the suction hose nut (1) from the accumulator (3).
  5. Remove the suction hose (2) from the accumulator (3).
  6. Remove the suction hose (2) from the vehicle.
  7. Discard all of the used sealing washers.
  8. Cap all of the A/C system openings.
  1. Install the suction hose assembly to the vehicle.
  2. Install the new sealing washers. Refer to «Sealing Washer Replacement»(ref-187267-S32968695222005083100000) .
  3. Install the suction hose (2) to the accumulator (3).
  4. Install the suction hose nut (1) to the accumulator (3). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install the suction hose (1) to the compressor (4).
  6. Install the suction hose mounting bolt (2) to the A/C Compressor (4). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  7. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  8. Leak test the fittings of the component using the J 39400-A . See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  2. Remove the evaporator tube nut (2) from the condenser (1).
  3. Remove the evaporator tube (3) from the condenser (1).
  4. Remove the evaporator tube nut (1) from the evaporator.
  5. Remove the evaporator tube (4) from the evaporator.
  6. Remove the evaporator tube (4) from the body retaining clip (3).
  7. Remove the evaporator tube (3) from the vehicle.
  8. Discard all of the used sealing washers.
  9. Cap all of the open connections.
  1. Install the new sealing washers. Refer to «Sealing Washer Replacement»(ref-187267-S32968695222005083100000) .
  2. Install the evaporator tube (4) to the body retaining clip (3).
  3. Install the evaporator tube (4) to the evaporator.
  4. Install the evaporator tube nut (1) to the evaporator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install the evaporator tube (3) to the condenser (1).
  6. Install the evaporator tube nut (2) to the condenser (1). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  7. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  8. Leak test the fittings of the components using the J 39400-A . See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  1. Recover the refrigerant from the system. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  2. Remove the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-187222-S34733330812005083100000) in Engine Controls - 6.0 L.
  3. Remove the nuts (4) from the A/C refrigerant filter (1).
  4. Remove the A/C refrigerant filter (5) from the evaporator tube (4).
  1. Coat the O-rings (2) with 525 viscosity refrigerant oil.
  2. Install the O-rings (2) to the evaporator tube.
  3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator.
  4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten: Tighten the nuts to 15 N.m (11 lb ft).
  5. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  6. Leak test the fittings of the repaired or reinstalled component using the J 39400-A . See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  7. Install the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-187222-S34733330812005083100000) in Engine Controls - 6.0 L.

Expansion (Orifice) Tube Replacement

Tools Required

  1. J 26549-E Orifice Tube Remover. See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  2. J 39400-A Halogen Leak Detector. See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  2. Loosen the nut from the evaporator tube fitting.
  3. Use the J 26549-E in order to remove the orifice tube (1) from the evaporator tube (2). See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  4. Cap or plug the open line.
  1. Uncap or unplug the evaporator tube.
  2. Lubricate the new O-ring using new 525 viscosity refrigerant oil.
  3. Install the new O-ring seal.
  4. Install the orifice tube (1) to the evaporator tube (2). Coat the O-ring seal with 525 viscosity refrigerant oil. Insert the short screen end of the new orifice (1) into the evaporator tube.
  5. Connect the evaporator tube at the fitting. Tighten: Tighten the fitting to 25 N.m (18 lb ft).
  6. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  7. Leak test the fittings of the repaired component using J 39400-A . See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  1. Remove the cover from the underhood convenience center (1).
  2. Remove the A/C compressor relay (1) from the convenience center (2).
  1. Install the A/C compressor relay (1) to the convenience center (2).
  2. Install the cover to the underhood convenience center (1).
  1. Disconnect the electrical connector from the A/C low pressure switch.
  2. Remove the A/C low pressure switch from the accumulator.
  3. Remove the O-ring and discard.
  1. Install the NEW O-ring seal to the switch. Refer to «O-Ring Replacement»(ref-187267-S41632393972005083100000) .
  2. Install the A/C low pressure switch to the accumulator. Tighten: Tighten the switch to 6 N.m (53 lb in).
  3. Connect the electrical connector to the A/C low pressure switch.
  1. Disconnect the electrical connector from the A/C refrigerant pressure sensor.
  2. Remove the A/C refrigerant pressure sensor from the evaporator tube.
  1. Install the A/C refrigerant pressure sensor. Tighten: Tighten the switch to 6 N.m (53 lb in).
  2. Connect the electrical connector to the A/C refrigerant pressure sensor.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  2. Remove the transmission oil cooler. Refer to «Transmission Fluid Auxiliary Cooler Replacement»(ref-187261-S20217205722005083100000) in Automatic Transmission - 4L60-E.
  3. Remove the power steering cooler. Refer to «Power Steering Cooler Replacement»(ref-187273-S35344124422005083100000) in Power Steering System.
  4. Remove the bolt and nut from the left hood spring.
  5. Remove the bolt and nut from the right hood spring.
  6. Remove the nut (1) from the condenser (2).
  7. Remove the compressor discharge hose assembly (3) from the condenser (2).
  8. Remove the evaporator tube nut (2) from the condenser (1).
  9. Remove the evaporator tube (3) from the condenser (1).
  10. Remove the bolts (2) from the condenser (3).
  11. Remove the condenser (3) from the vehicle.
  1. Add the proper amount of PAG oil to the condenser. Refer to «Refrigerant System Capacities»(ref-187267-S27339359592005083100000) .
  2. Install the condenser (3) to the vehicle.
  3. Install the bolts (2) to the condenser (3). Tighten: Tighten the bolts to 9 N.m (80 lb in).
  4. Install the new sealing washers. Refer to «Sealing Washer Replacement»(ref-187267-S32968695222005083100000) .
  5. Install the evaporator tube (3) to the condenser (1).
  6. Install the evaporator tube nut (2) to the condenser (1). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  7. Install the compressor discharge hose (3) to the condenser (2).
  8. Install the compressor discharge hose nut (1) to the condenser (2). Tighten: Tighten the nut to 16 N.m (12 lb ft).
  9. Install the transmission oil cooler. Refer to «Transmission Fluid Auxiliary Cooler Replacement»(ref-187261-S20217205722005083100000) in Automatic Transmission - 4L60-E.
  10. Install the power steering cooler. Refer to «Power Steering Cooler Replacement»(ref-187273-S35344124422005083100000) in Power Steering System.
  11. Install the bolt and nut from the right hood spring. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  12. Install the bolt and nut from the left hood spring. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  13. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  14. Leak test the fittings of the component using the J 39400-A . See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  2. Disconnect the electrical connector from the A/C low pressure switch.
  3. Remove the compressor hose nut from the accumulator.
  4. Remove the compressor hose from the accumulator.
  5. Remove the nut (2) from the evaporator fitting.
  6. Remove the accumulator bracket nut (4) from the retaining stud.
  7. Remove the accumulator (3).
  8. Remove the retaining bracket bolt (5).
  9. Remove the retaining bracket (6) from the accumulator (3).
  10. Remove and discard the O-ring seals.
  1. Add the proper amount of PAG oil to the accumulator. Refer to «Refrigerant System Capacities»(ref-187267-S27339359592005083100000) .
  2. Install new O-ring seals. Refer to «O-Ring Replacement»(ref-187267-S41632393972005083100000) .
  3. Install the retaining bracket (6) to the accumulator.
  4. Install the retaining bracket bolt (5). Tighten: Tighten the bolt to 10 N.m (89 lb in).
  5. Install the accumulator (3).
  6. Install the accumulator bracket nut (4). Tighten: Tighten the nut to 9 N.m (80 lb in).
  7. Install the nut (2) to the evaporator fitting. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  8. Install the compressor hose to the accumulator.
  9. Install the compressor hose nut to the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  10. Connect the electrical connector to the A/C low pressure switch.
  11. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(ref-187267-S22246222552005083100000) .
  12. Leak test the fittings of the component using the J 39400-A . See «Special Tools and Equipment»(ref-187267-S04209045862005083100000) .
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-187257-S14804005252005083100000) in Engine Cooling.
  2. Using the J 43181 disconnect the inlet heater hose from the heater core. Install the J 43181 to the heater core pipe. Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core.
  3. Using the J 43181 disconnect the surge tank outlet hose from the heater core. Install the J 43181 to the heater core pipe. Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core.
  4. Remove the accumulator. Refer to «Accumulator Replacement»(ref-187267-S21965474862005083100000) .
  5. Remove the instrument panel carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-187217-S30750948582005083100000) in Instrument Panel, Gauges and Console.
  6. Remove the HVAC module drain hose.
  7. Disconnect the electrical harnesses and the ground connections from the HVAC module assembly.
  8. Remove the nuts (4) from the HVAC module assembly (2).
  9. Remove the bolts (3) from the HVAC module assembly (2).
  10. Remove the HVAC module assembly (2) from the vehicle (1).
  1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary.
  2. Install the HVAC module assembly (2) to the vehicle (1).
  3. Install the nuts (4) to the HVAC module assembly (2). Tighten: Tighten the nuts to 9 N.m (80 lb in).
  4. Install the bolts (4) to the HVAC module assembly (2). Tighten: Tighten the bolts to 4 N.m (35 lb in).
  5. Connect the electrical harnesses and the ground connections.
  6. Install the HVAC module drain hose.
  7. Install the instrument panel carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-187217-S30750948582005083100000) in Instrument Panel, Gauges and Console.
  8. Install the accumulator. Refer to «Accumulator Replacement»(ref-187267-S21965474862005083100000) .
  9. Install the surge tank outlet hose to the heater core.
  10. Pull the surge tank outlet hose to ensure the connection.
  11. Install the inlet heater hose to the heater core. IMPORTANT: Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  12. Pull the inlet heater hose to ensure the connection.
  13. Fill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-187257-S14804005252005083100000) in Engine Cooling.
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  2. Disconnect the electrical connector from the recirculation actuator.
  3. Remove the harness from the evaporator cover.
  4. Remove the screws from the recirculation actuator.
  5. Remove the recirculation actuator from the HVAC module.
  6. Remove the screws from the evaporator cover (1).
  7. Remove the evaporator cover (1) from the HVAC module (2).
  8. Remove the evaporator cowl gasket (1) from the evaporator (2).
  9. Remove the evaporator core (1) from the HVAC module (2).
  1. Add the proper amount of PAG oil the evaporator. Refer to «Refrigerant System Capacities»(ref-187267-S27339359592005083100000) .
  2. Install the evaporator core (1) to the HVAC module (2).
  3. Install the evaporator cowl gasket (1) to the evaporator (2).
  4. Install the evaporator cover (1) to the HVAC module (2).
  5. Install the screws to the evaporator cover (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  6. Install the recirculation actuator to the HVAC module.
  7. Install the screws to the recirculation actuator. Tighten: Tighten the screws to 2 N.m (18 lb in).
  8. Install the harness to the evaporator cover.
  9. Connect the electrical connector to the recirculation actuator (1).
  10. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-187257-S14804005252005083100000) in Engine Cooling.
  2. Using the J 43181 disconnect the inlet heater hose from the heater core. Install the J 43181 to the inlet heater core pipe. Close the tool around the inlet heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
  3. Remove the heater inlet hose (1) from the mounting clip (2).
  4. Reposition the heater inlet hose clamp from the engine.
  5. Remove the heater inlet hose (1) from the engine.
  6. Remove the heater inlet hose (1) from the vehicle.
  1. Install the heater inlet hose (1) to the vehicle.
  2. Install the heater inlet hose (1) to the engine.
  3. Install the heater inlet hose clamp to the engine.
  4. Install the heater inlet hose (1) to the mounting clip (2).
  5. Connect the heater inlet hose to the heater core.
  6. Pull the heater inlet hose to ensure the connection.
  7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187257-S14804005252005083100000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-187257-S14804005252005083100000) .
  2. Using the J 43181 disconnect the inlet heater hose from the heater core. Install the J 43181 to the heater core inlet pipe. Close the tool around the heater core inlet pipe. Firmly pull the tool into the quick connect end of the heater inlet hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
  3. Using the J 43181 disconnect the surge tank outlet hose from the heater core outlet. Install the J 43181 to the heater core outlet pipe. Close the tool around the heater core outlet pipe. Firmly pull the tool into the quick connect end of the heater outlet hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
  4. Remove the surge tank outlet hose (3) from the mounting clip (2).
  5. Reposition the surge tank outlet hose clamp (3) from the engine (2).
  6. Remove the surge tank outlet hose (6) from the engine (2).
  7. Reposition the surge tank outlet hose clamp (5) from the surge tank (2).
  8. Remove the surge tank outlet hose (3) from the surge tank (2).
  9. Remove the surge tank outlet hose (3) from the vehicle.
  1. Install the surge tank outlet hose (3) to the vehicle.
  2. Install the surge tank outlet hose (3) to the surge tank (2).
  3. Install the surge tank outlet hose clamp (5) to the surge tank (2).
  4. Install the surge tank outlet hose (6) to the engine (2).
  5. Install the surge tank outlet hose clamp (3) to the engine (2).
  6. Install the surge tank outlet hose to the mounting clip.
  7. Install the surge tank outlet hose (3) to the mounting clip (2).
  8. Install the surge tank outlet hose to the heater core outlet pipe.
  9. Pull the surge tank outlet hose to ensure the connection.
  10. Install the heater inlet hose to the heater core. IMPORTANT: Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  11. Pull the inlet heater inlet hose to ensure the connection.
  12. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187257-S14804005252005083100000) .
  1. Remove the sound insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-187217-S22609352492005083100000) in Instrument Panel, Gauges, and Console.
  2. Disconnect the electrical connector (2) from the blower motor (1).
  3. Remove the screws from the blower motor (1).
  4. Remove the blower motor (1) from the HVAC module (3).
  5. Remove the retainer from the blower motor impeller. Discard the retainer.
  6. Remove the blower motor impeller from the blower motor (1).
  1. Install the blower motor impeller to the blower motor (1).
  2. Install the new retainer to the blower motor impeller.
  3. Install the blower motor (1) to the HVAC module (3).
  4. Install the screws to the blower motor (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Connect the electrical connector (2) to the blower motor (1).
  6. Install the sound insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-187217-S22609352492005083100000) in Instrument Panel, Gauges, and Console.
  1. Remove the sound insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-187217-S22609352492005083100000) in Instrument Panel, Gauges, and Console.
  2. Disconnect the electrical connector (2) from the blower motor (1).
  3. Remove the screws from the blower motor (1).
  4. Remove the blower motor (1) from the HVAC module (3).
  5. Remove the retainer from the blower motor impeller. Discard the retainer.
  6. Remove the blower motor impeller from the blower motor (1).
  1. Install the blower motor impeller to the blower motor (1).
  2. Install the new retainer to the blower motor impeller.
  3. Install the blower motor (1) to the HVAC module (3).
  4. Install the screws to the blower motor (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Connect the electrical connector (2) to the blower motor (1).
  6. Install the sound insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-187217-S22609352492005083100000) in Instrument Panel, Gauges, and Console.
  1. Remove the I/P trim panel. Refer to «Trim Pad Replacement - Instrument Panel (I/P) Upper»(ref-187217-S16609271192005083100000) in Instrument Panel, Gauges and Console.
  2. Remove the screw (1) from the air distribution duct (4).
  3. Remove the screws (3) from the air distribution duct (1).
  4. Remove the air distribution duct (1) from the I/P trim panel (2).
  1. Install the air distribution duct (1) to the I/P trim Panel (2).
  2. Install the screws (3) to the air distribution duct (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  3. Install the screw (1) to the air distribution duct (4). Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Install the I/P trim panel. Refer to «Trim Pad Replacement - Instrument Panel (I/P) Upper»(ref-187217-S16609271192005083100000) in Instrument Panel, Gauges and Console.
  1. Use a flat bladed tool in order to remove the air deflector from the trim panel.
  2. Remove the air reflector.
  1. Align the air deflector into the opening in the trim panel accessory left.
  2. Push the air outlet into the trim panel until the deflector snaps into place.

Scheme 14

Scheme 14: Removal Procedure
Scheme 14: Removal Procedure

Using a flat bladed tool, remove the air deflector louver from the instrument panel.

  1. Align the air deflector into the opening in the trim panel I/P center.
  2. Push the air outlet into the trim panel until the deflector snaps into place.
  1. Use a flat bladed tool in order to remove the air deflector from the trim panel.
  2. Remove the air reflector louver.
  1. Align the air deflector into the opening in the trim panel accessory right.
  2. Push the air outlet into the trim panel until the deflector snaps into place.
  1. Remove the console. Refer to «Console Replacement»(ref-187217-S27783040252005083100000) in Instrument Panel, Gauges and Console.
  2. Remove the push pin (1).
  3. Remove the air outlet duct-rear (3) from the console support bracket (1).
  1. Install the air outlet duct-rear (3) to the console support bracket (1).
  2. Install the push pin (1).
  3. Install the console. Refer to «Console Replacement»(ref-187217-S27783040252005083100000) in Instrument Panel, Gauges and Console.
  1. Remove the push pin from the left floor air outlet duct (3).
  2. Remove the left floor duct (3) from the HVAC module assembly (2).
  1. Install the left floor air outlet duct (3) to the HVAC module assembly (2).
  2. Install the push pin to the left floor air outlet duct (3).
  1. Remove the right I/P insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-187217-S22609352492005083100000) in Instrument Panel, Gauges, and Console.
  2. Remove the screw (5) from the right floor air outlet duct (4).
  3. Remove the right floor air outlet duct (4) from the HVAC module assembly (2).
  1. Install the right floor air outlet duct (4) to the HVAC module assembly (2).
  2. Install the screw (5) to the right floor air outlet duct (4). Tighten: Tighten the screw to 1.6 N.m (14 lb in).
  3. Install the right I/P insulator panel. Refer to «Insulator Replacement - Instrument Panel (I/P)»(ref-187217-S22609352492005083100000) in Instrument Panel, Gauges, and Console.
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  2. Disconnect the electrical connector (3) from the mode actuator (4).
  3. Remove the screws from the mode actuator (4).
  4. Remove the mode actuator (4) from the HVAC module assembly (1).
  5. Remove the wiring harness from the air distribution housing (1).
  6. Remove the screws from the air distribution housing (1).
  7. Remove the air distribution housing (1) from the HVAC module assembly (2).
  8. Remove the screws from the upper recirulation housing (1).
  9. Remove the upper recirulation housing (1) from the HVAC module assembly (2).
  10. Remove the screws from the lower recirulation housing (1).
  11. Remove the lower recirulation housing (1) from the HVAC module assembly (2).
  12. Remove the wiring harness from the HVAC module assembly.
  13. Remove the screws from the HVAC module assembly.
  14. Remove the upper HVAC module case (1) from the lower HVAC module case (2).
  15. Remove the right temperature door (2) to the upper HVAC module case (1).
  1. Install the right temperature door (2) to the upper HVAC module case (1).
  2. Install the upper HVAC module case (1) to the lower HVAC module case (2).
  3. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Install the wiring harness to the HVAC module assembly.
  5. Install the lower recirulation housing (1) to the HVAC module assembly (2).
  6. Install the screws to the lower recirulation housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  7. Install the upper recirulation housing (1) to the HVAC module assembly (2).
  8. Install the screws to the upper recirulation housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  9. Install the air distribution housing (1) to the HVAC module assembly (2).
  10. Install the screws to the air distribution housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  11. Install the wiring harness to the air distribution housing (1).
  12. Install the mode actuator (4) to the HVAC module assembly (1).
  13. Install the screws to the mode actuator (4). Tighten: Tighten the screws to 2 N.m (18 lb in).
  14. Connect the electrical connector (3) to the mode actuator (4).
  15. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  2. Disconnect the electrical connector (3) from the mode actuator (4).
  3. Remove the screws from the mode actuator (4).
  4. Remove the mode actuator (4) from the HVAC module assembly (1).
  5. Remove the wiring harness from the air distribution housing (1).
  6. Remove the screws from the air distribution housing (1).
  7. Remove the air distribution housing (1) from the HVAC module assembly (2).
  8. Remove the screws from the upper recirulation housing (1).
  9. Remove the upper recirulation housing (1) from the HVAC module assembly (2).
  10. Remove the screws from the lower recirulation housing (1).
  11. Remove the lower recirulation housing (1) from the HVAC module assembly (2).
  12. Remove the wiring harness from the HVAC module assembly.
  13. Remove the screws from the HVAC module assembly.
  14. Remove the upper HVAC module case (1) from the lower HVAC module case (2).
  15. Remove the HVAC module chamber plate (1) from the lower HVAC module case (3).
  16. Remove the left temperature door (2) from the lower HVAC module case (3).
  1. Install the left temperature door (2) to the lower HVAC module case (3).
  2. Install the HVAC module chamber plate (1) to the lower HVAC module case (3).
  3. Install the upper HVAC module case (1) to the lower HVAC module case (2).
  4. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the wiring harness to the HVAC module.
  6. Install the lower recirulation housing (1) to the HVAC module assembly (2).
  7. Install the screws to the lower recirulation housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  8. Install the upper recirulation housing (1) to the HVAC module assembly (2).
  9. Install the screws to the upper recirulation housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  10. Install the air distribution housing (1) to the HVAC module assembly (2).
  11. Install the screws to the air distribution housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  12. Install the wiring harness to the air distribution housing (1).
  13. Install the mode actuator (4) to the HVAC module assembly (1).
  14. Install the screws to the mode actuator (4). Tighten: Tighten the screws to 2 N.m (18 lb in).
  15. Connect the electrical connector (3) to the mode actuator (4).
  16. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  2. Disconnect the electrical connector (3) from the mode actuator (4).
  3. Remove the screws from the mode actuator (4).
  4. Remove the mode actuator (4) from the HVAC module assembly (1).
  5. Remove the wiring harness from the air distribution housing (1).
  6. Remove the screws from the air distribution housing (1).
  7. Remove the air distribution housing (1) from the HVAC module assembly (2).
  8. Remove the mode door (2) from the air distribution housing (1).
  1. Install the mode door (1) to the air distribution housing (1).
  2. Install the air distribution housing (1) to the HVAC module assembly (2).
  3. Install the screws to the air distribution housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Install the wiring harness to the air distribution housing (1).
  5. Connect the electrical connector (3) to the mode actuator (4).
  6. Install the screws to the mode actuator (4).
  7. Install the mode actuator (4) to the HVAC module assembly (1).
  8. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  2. Disconnect the electrical connector (3) from the mode actuator (4).
  3. Remove the screws from the mode actuator (4).
  4. Remove the mode actuator (4) from the HVAC module assembly (1).
  5. Remove the wiring harness from the air distribution housing (1).
  6. Remove the screws from the air distribution housing (1).
  7. Remove the air distribution housing (1) from the HVAC module assembly (2).
  8. Remove the screws from the air distribution housing (1).
  9. Separate the air distribution housing halves.
  10. Remove the lever from the upper mode door (4).
  11. Remove the lever from the defrost door (2).
  12. Remove the door assembly (3) from the left air distribution housing (1).
  13. Remove the mode door (4) from the door assembly (3).
  1. Install the mode door (4) to the door assembly (3).
  2. Install the door assembly (3) to the left air distribution housing (1).
  3. Install the lever to the defrost door (2).
  4. Install the lever to the upper mode door (4).
  5. Install the air distribution housing halves.
  6. Install the screws to the air distribution housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  7. Install the air distribution housing (1) to the HVAC module assembly (2).
  8. Install the screws to the air distribution housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  9. Install the wiring harness to the air distribution housing (1).
  10. Connect the electrical connector (3) to the mode actuator (4).
  11. Install the mode actuator (4) to the HVAC module assembly (1).
  12. Install the screws to the mode actuator (4). Tighten: Tighten the screws to 2 N.m (18 lb in).
  13. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  2. Remove the wiring harness from the recirculation housing (1).
  3. Remove the screws from the upper recirculation housing (1).
  4. Remove the upper recirculation housing (1) from the HVAC module assembly (2).
  5. Disconnect the electrical connector from the recirculation actuator (1).
  6. Remove the screws from the recirculation actuator (1).
  7. Remove the recirculation actuator (1) from the recirculation housing (2).
  8. Remove the recirculation door (1) from the recirculation housing (2).
  1. Install the recirculation door (1) to the recirculation housing (2).
  2. Install the recirculation actuator (1) to the recirculation housing (2).
  3. Install the screws to the recirculation actuator (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Connect the electrical connection to the recirculation actuator (1).
  5. Install the upper recirculation housing (1) to the HVAC module assembly (2).
  6. Install the screws to the upper recirculation housing (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  7. Install the wiring harness to the recirculation housing (1).
  8. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .
  2. Remove the screws from the heater core cover.
  3. Remove the heater core cover (1) from the HVAC module assembly (2).
  4. Remove the heater core cowl gasket (1) from the heater core (2).
  5. Remove the heater core (1) from the HVAC module assembly (2).
  1. Install the heater core (1) to the HVAC module assembly (2).
  2. Install the heater core cowl gasket (1) to the HVAC module assembly (2).
  3. Install the heater core cover (1) to the HVAC module assembly (2).
  4. Install the screws to the heater core cover (1). Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-187267-S10652867022005083100000) .

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