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Home/Hummer/H2/Hummer H2 I рестайлинг (2007-2009)/Repair manual/Automatic HVAC System/Heating, Ventilation, and Air Conditioning: Removal & Insta…
Contents Section: Automatic HVAC System All sections

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

Automatic HVAC System 16 illustrations ~5819 words

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-299130-S36373810622008092200000) .
  2. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-299178-S36596592732008092200000) .
  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-299130-S10490626852008092200000) .

Installation Procedure

  1. Add the proper amount of PAG oil to the compressor crankcase. Refer to «Refrigerant System Capacities»(ref-299130-S19315200972008092200000) .
  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-299130-S23857988332008092200000) .
  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 «Air Conditioning Compressor Belt Replacement»(ref-299183-S28408286442008092200000) .
  12. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-299178-S36596592732008092200000) .
  13. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-299130-S36373810622008092200000) .
  14. Leak test the fittings of the component using the J 39400-A .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299137-S12533882312008092200000) .
  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-299130-S02487172852008092200000) .
  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-299130-S02487172852008092200000) .
  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-299130-S36373810622008092200000) .
  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-299130-S23857988332008092200000)
  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-299130-S36373810622008092200000) .
  10. Leak test the fittings of the component using the J 39400-A .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-299130-S36373810622008092200000) .
  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-299130-S23857988332008092200000) .
  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-299130-S36373810622008092200000) .
  8. Leak test the fittings of the component using the J 39400-A .
  1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-299130-S36373810622008092200000) .
  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-299130-S23857988332008092200000) .
  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-299130-S36373810622008092200000) .
  8. Leak test the fittings of the components using the J 39400-A .

Expansion (Orifice) Tube Replacement

Tools Required

  1. J 26549-E Orifice Tube Remover
  2. J 39400-A Halogen Leak Detector
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-299130-S36373810622008092200000) .
  2. Loosen the nut from the evaporator tube fitting.
  3. Use the J 26549-E in order to remove the orifice tube (1) from the evaporator tube (2).
  4. Cap or plug the open line.
  1. Uncap or unplug the evaporator tube.
  2. Lubricate the new O-ring using new 525 viscosity refrigerant oil.
  3. Install the new O-ring seal.
  4. Install the orifice tube (1) to the evaporator tube (2). Coat the O-ring seal with 525 viscosity refrigerant oil. Insert the long screen end of the new orifice (1) into the evaporator tube (2).
  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-299130-S36373810622008092200000) .
  7. Leak test the fittings of the repaired component using J 39400-A .
  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-299130-S01637741562008092200000) .
  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-299130-S36373810622008092200000) .
  2. Remove the transmission oil cooler. Refer to «Transmission Fluid Auxiliary Cooler Replacement»(ref-299125-S30418831802008092200000) .
  3. Remove the power steering cooler. Refer to «Power Steering Fluid Cooler Replacement»(ref-299162-S10680083622008092200000) .
  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-299130-S19315200972008092200000) .
  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-299130-S23857988332008092200000) .
  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-299125-S30418831802008092200000) .
  10. Install the power steering cooler. Refer to «Power Steering Fluid Cooler Replacement»(ref-299162-S10680083622008092200000) .
  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-299130-S36373810622008092200000) .
  14. Leak test the fittings of the component using the J 39400-A .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-299130-S36373810622008092200000) .
  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-299130-S19315200972008092200000) .
  2. Install new O-ring seals. Refer to «O-Ring Replacement»(ref-299130-S01637741562008092200000) .
  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-299130-S36373810622008092200000) .
  12. Leak test the fittings of the component using the J 39400-A .
  1. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .
  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-299130-S07421156762008092200000) .
  5. Remove the instrument panel carrier. Refer to «Instrument Panel Carrier Replacement»(ref-299121-S08227204762008092200000) .
  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 Carrier Replacement»(ref-299121-S08227204762008092200000) .
  8. Install the accumulator. Refer to «Accumulator Replacement»(ref-299130-S07421156762008092200000) .
  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 «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-299130-S12348617812008092200000) .
  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 «HVAC Module Assembly Replacement»(ref-299130-S12348617812008092200000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .
  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 «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .
  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 «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .

Scheme 2

Scheme 2: Blower Motor Control Module Replacement
Scheme 2: Blower Motor Control Module Replacement
CalloutComponent Name
Preliminary Procedure Remove the I/P insulator panel. Refer to Instrument Panel Insulator Panel Replacement . Disconnect the blower motor control module electrical connector.
1Blower Motor Control Module Screw (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2Blower Motor Control Module
NOTE
Refer to Fastener Notice .
  1. If equipped, remove the I/P insulator panel. Refer to «Instrument Panel Insulator Panel Replacement»(ref-299121-S27471297422008092200000) .
  2. Remove the blower motor insulating cover screws.
  3. Disconnect the electrical connector from the blower motor.
  4. Remove the blower motor insulating cover.
  5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module.
  6. Remove the blower motor.
  1. Install the blower motor.
  2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place.
  3. Install the blower motor insulating cover.
  4. Connect the electrical connector to the blower motor.
  5. Install the blower motor insulating cover screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  6. If equipped, install the I/P insulator panel. Refer to «Instrument Panel Insulator Panel Replacement»(ref-299121-S27471297422008092200000) .

Scheme 3

Scheme 3: Air Distributor Duct Replacement
Scheme 3: Air Distributor Duct Replacement
CalloutComponent Name
Preliminary Procedure: Remove I/P carrier assembly. Refer to Instrument Panel Carrier Replacement .
1I/P Air Outlet Distribution Duct Screw (5)
2I/P Air Outlet Distribution Duct
  1. Remove the console. Refer to «Front Floor Console Replacement»(ref-299121-S40892247102008092200000) .
  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 «Front Floor Console Replacement»(ref-299121-S40892247102008092200000) .
  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 «Instrument Panel Insulator Panel Replacement»(ref-299121-S27471297422008092200000) .
  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 «Instrument Panel Insulator Panel Replacement»(ref-299121-S27471297422008092200000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-299130-S12348617812008092200000) .
  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 «HVAC Module Assembly Replacement»(ref-299130-S12348617812008092200000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-299130-S12348617812008092200000) .
  2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer.
  3. If equipped remove the HVAC module assembly screws.
  4. Remove the upper HVAC module case (3) from the lower HVAC module case (10).
  5. Remove the air temperature separator plate (5) from the lower HVAC module case (10).
  6. Remove the left temperature door (11) from the lower HVAC module case (10).
  1. Install the left temperature door (11) to the lower HVAC module case (10).
  2. Install the air temperature separator plate (5) to the lower HVAC module case (10).
  3. Install the upper HVAC module case (3) to the lower HVAC module case (10).
  4. Install the screws to the HVAC module assembly. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  5. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-299130-S12348617812008092200000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-299130-S12348617812008092200000) .
  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 assembly. Refer to «HVAC Module Assembly Replacement»(ref-299130-S12348617812008092200000) .
IMPORTANTThe upper mode door (6) is serviced with the upper HVAC module case (3).
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-299130-S12348617812008092200000) .
  2. Disconnect the electrical connector (3) from the mode actuator (4).
  3. Remove the screws from the mode actuator (4).
  4. Remove the mode actuator (4) from the HVAC module assembly (1).
  5. If equipped remove the heat stakes (1) from the HVAC module (2) with a 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 assembly. Refer to «HVAC Module Assembly Replacement»(ref-299130-S12348617812008092200000) .

Scheme 4

Scheme 4: Recirculation Door Replacement
Scheme 4: Recirculation Door Replacement
CalloutComponent Name
Preliminary Procedure: Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
1Air Inlet Assembly Screw (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in) Procedure: Tighten the fasteners equally to ensure the air inlet assembly seats evenly.
2Air Inlet Assembly (Recirculation Door) Procedure Disconnect the electrical connectors. When replacing the Recirculation Door, transfer all necessary components. Re-calibrate the Recirculation Actuator. Refer to Actuator Recalibration Tip: The Recirculation Door is part of the Air Inlet Assembly.
NOTE
Refer to Fastener Notice .

Scheme 5

Scheme 5: Heater Core Replacement
Scheme 5: Heater Core Replacement
CalloutComponent Name
Preliminary Procedure Remove the HVAC module. Refer to HVAC Module Assembly Replacement . Disconnect the wiring harness retainer from the heater core cover.
1Heater Core Cover Screw NOTE: Refer to Fastener Notice . 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
NOTE
Refer to Fastener Notice .
  1. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .
  2. Remove the air cleaner resonator outlet duct replacement «Air Cleaner Resonator Outlet Duct Replacement»(ref-299142-S39860654132008092200000) .
  3. Squeeze the plastic retainer release tabs.
  4. Pull the hose connection apart.
  5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299137-S12533882312008092200000) .
  6. Remove the right assist step if necessary. Refer to «Assist Step Replacement (w/WS2, BVX)»(ref-299135-S18096453502008092200000) or «Assist Step Replacement (Tubular BVE)»(ref-299135-S20242574652008092200000) .
  7. Remove the front wheelhouse liner if necessary. Refer to «Wheelhouse Panel Replacement»(ref-299135-S07316607702008092200000) .
  8. Remove the auxiliary heater tubes connector nuts (2) from the intermediate connection point.
  9. Remove the auxiliary heater tubes clip push pins (1) from vehicle frame locations.
  10. Remove the auxiliary heater tubes (2) from vehicle.
  11. Remove auxiliary heater tubes clip retaining push pin/bolt (1) if necessary.
  12. Use a flat blade release tool to open retaining clips (2).
  13. Remove auxiliary heater tubes (3) from retaining clips.
IMPORTANTThe replacement A/C and heater pipes are shipped in front and rear sections.
  1. Install the auxiliary heater tubes (3) to the retaining clips (2).
  2. Install the auxiliary heater tubes (3) to the vehicle.
  3. Install the auxiliary heater tubes clip push pins (1) to vehicle frame locations.
  4. Install the auxiliary heater tube connection nuts (2) to the intermediate connection point. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
  5. Install the auxiliary heater tubes (1) to the main heater hose connections.
  6. Install the front wheelhouse liner if necessary. Refer to «Wheelhouse Panel Replacement»(ref-299135-S07316607702008092200000) .
  7. Install the right assist step if necessary. Refer to «Assist Step Replacement (w/WS2, BVX)»(ref-299135-S18096453502008092200000) or «Assist Step Replacement (Tubular BVE)»(ref-299135-S20242574652008092200000) .
  8. Lower the vehicle.
  9. Fill the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .
  1. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299137-S12533882312008092200000) .
  3. Remove the right assist step if necessary. Refer to «Assist Step Replacement (w/WS2, BVX)»(ref-299135-S18096453502008092200000) or «Assist Step Replacement (Tubular BVE)»(ref-299135-S20242574652008092200000) .
  4. Remove the rear wheelhouse liner. Refer to «Wheelhouse Panel Replacement»(ref-299135-S07316607702008092200000) .
  5. Remove the auxiliary heater tubes connector nuts (2) from the intermediate connection point.
  6. Pinch the tabs together at auxiliary HVAC module fittings to remove the auxiliary heater tubes (1).
  7. Remove the heater tubes retaining push pins (1) at the frame locations.
  8. Remove the heater tubes retaining bolt (2) at the frame location.
  9. Remove the auxiliary heater tubes (3) from the frame.
  10. Remove the auxiliary heater tubes from the vehicle.
  11. Remove auxiliary heater tubes clip retaining push pin/bolt (1) if necessary.
  12. Use a flat-bladed release tool to open retaining clips (2).
  13. Remove auxiliary heater tubes from vehicle.
IMPORTANTThe replacement A/C and heater pipes are shipped in front and rear sections.
  1. Install the auxiliary heater tubes (3) to the retaining clips (2).
  2. Install the auxiliary heater tubes (3) to the vehicle.
  3. Install the auxiliary heater tube nut (2). Tighten: Tighten the nut to 7 N.m (62 lb in).
  4. Install the auxiliary heater tube push pins (1).
  5. Install the auxiliary heater tubes (1) to the auxiliary HVAC module.
  6. Install the auxiliary heater tube connection nuts (2) to the intermediate connection point. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
  7. Install the rear wheelhouse liner. Refer to «Wheelhouse Panel Replacement»(ref-299135-S07316607702008092200000) .
  8. Install the right assist step if necessary. Refer to «Assist Step Replacement (w/WS2, BVX)»(ref-299135-S18096453502008092200000) or «Assist Step Replacement (Tubular BVE)»(ref-299135-S20242574652008092200000) .
  9. Lower the vehicle.
  10. Fill the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .

Scheme 6

Scheme 6: Auxiliary Blower Control Module Replacement
Scheme 6: Auxiliary Blower Control Module Replacement
CalloutComponent Name
Preliminary Procedure Remove the body side trim panel - right side. Refer to Body Side Trim Panel Replacement - Right Side . Disconnect any wiring connectors.
1Auxiliary Blower Motor Control Module Screw (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
2Auxiliary Blower Motor Control Module
NOTE
Refer to Fastener Notice .

Scheme 7

Scheme 7: Auxiliary Blower Motor Replacement
Scheme 7: Auxiliary Blower Motor Replacement
CalloutComponent Name
Preliminary Procedure Remove the body side trim panel - right side. Refer to Body Side Trim Panel Replacement - Right Side . Disconnect any wiring connectors. Disconnect the auxiliary blower motor cooling tube.
1Auxiliary Blower Motor Screw (Qty: 3) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
2Auxiliary Blower Motor
NOTE
Refer to Fastener Notice .

Scheme 8

Scheme 8: Auxiliary Air Distributor Lower Duct Replacement
Scheme 8: Auxiliary Air Distributor Lower Duct Replacement
CalloutComponent Name
Preliminary Procedure Remove the body side trim panel - right side. Refer to Body Side Trim Panel Replacement - Right Side . Disconnect any wiring connectors.
1Auxiliary Air Distributor Duct - Lower Nut NOTE: Refer to Fastener Notice . Tighten: 3 N.m (27 lb in)
2Auxiliary Air Distributor Duct - Lower
NOTE
Refer to Fastener Notice .

Scheme 9

Scheme 9: Auxiliary Air Distributor Duct Replacement - Upper
Scheme 9: Auxiliary Air Distributor Duct Replacement - Upper
CalloutComponent Name
Preliminary Procedure Remove the body side trim panel - right side. Refer to Body Side Trim Panel Replacement - Right Side . Disconnect any wiring connectors.
1Auxiliary Air Distributor Duct - Upper Bolt NOTE: Refer to Fastener Notice . Tighten: 3 N.m (27 lb in)
2Auxiliary Air Distributor Duct - Upper Procedure: Squeeze upper duct at headliner to remove.
NOTE
Refer to Fastener Notice .

Scheme 10

Scheme 10: Auxiliary Heater Core Replacement
Scheme 10: Auxiliary Heater Core Replacement
CalloutComponent Name
Preliminary Procedure Remove the auxiliary HVAC module. Refer to Auxiliary HVAC Module Replacement . Disconnect any wiring connectors. Invert the auxiliary HVAC module to access components.
1Auxiliary Heater Core Bracket Screw (Qty: 6) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
2Auxiliary Heater Core Tube Bracket
3Auxiliary HVAC Module Lower Case Seal
4Auxiliary A/C Evaporator Tube Bracket
5Auxiliary Heater Core Procedure: Slide the auxiliary heater core outward of the case for removal. Tip: Ensure the heater core seals are secure upon installation.
NOTE
Refer to Fastener Notice .

Scheme 11

Scheme 11: Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement
Scheme 11: Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement
CalloutComponent Name
Preliminary Procedure Remove the auxiliary evaporator core. Refer to Auxiliary Air Conditioning Evaporator Replacement . Disconnect any wiring connectors.
1Auxiliary A/C Evaporator Thermal Expansion Valve Bolt (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 4 N.m (35 lb in)
2Auxiliary A/C Evaporator Thermal Expansion Valve Tip: Ensure the new O-rings are used upon installation.
NOTE
Refer to Fastener Notice .

Scheme 12

Scheme 12: Auxiliary HVAC Module Replacement
Scheme 12: Auxiliary HVAC Module Replacement
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Raise the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the wheelhouse panel. Refer to Wheelhouse Panel Replacement . Remove auxiliary heater pipe - rear. Refer to Auxiliary Heater Pipe Replacement - Rear . Remove auxiliary evaporator tube - rear. Refer to Auxiliary Air Conditioning Evaporator Rear Tube Replacement . Partially drain the engine coolant from the coolant lines at the auxiliary HVAC module. Drain the heater core and plug lines/tubes to prevent loss of coolant. Lower the vehicle and remove the body side trim panel - right side. Refer to Body Side Trim Panel Replacement - Right Side . Disconnect wiring connector and ground(s) from HVAC module. Disconnect the auxiliary air distributor ducts. Refer to Auxiliary Air Distributor Lower Duct Replacement and Auxiliary Air Distributor Duct Replacement - Upper .
1Auxiliary HVAC Module Bolt (Qty: 4)
2Auxiliary HVAC Module NOTE: Refer to Fastener Notice . Tip: Ensure the HVAC module seal is secure upon installation. Tighten: 9 N.m (80 lb in)
NOTE
Refer to Fastener Notice .

Scheme 13

Scheme 13: Auxiliary Air Conditioning Evaporator Replacement
Scheme 13: Auxiliary Air Conditioning Evaporator Replacement
CalloutComponent Name
Preliminary Procedure Remove the auxiliary heater core. Refer to Auxiliary Heater Core Replacement . Disconnect any wiring connectors.
1Auxiliary Evaporator Core Tip: Ensure the evaporator core seals are secure upon installation.

Scheme 14

Scheme 14: Auxiliary Air Conditioning Evaporator and Blower Case Replacement - Inboard
Scheme 14: Auxiliary Air Conditioning Evaporator and Blower Case Replacement - Inboard
CalloutComponent Name
Preliminary Procedure Remove the auxiliary HVAC heater core. Refer to Auxiliary Heater Core Replacement . Disconnect any wiring connectors. Invert the auxiliary HVAC module to access components.
1Auxiliary A/C Evaporator and Blower Lower Case - Inboard Screw (Qty: 12) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
2Auxiliary A/C Evaporator and Blower Lower Case - Inboard Procedure Note the location and routing of the wiring harness to ensure proper reinstallation. When replacing the HVAC case, transfer all necessary components.
NOTE
Refer to Fastener Notice .

Scheme 15

Scheme 15: Auxiliary Air Conditioning Evaporator and Blower Case Replacement - Outboard
Scheme 15: Auxiliary Air Conditioning Evaporator and Blower Case Replacement - Outboard
CalloutComponent Name
Preliminary Procedure Remove the auxiliary HVAC heater core. Refer to Auxiliary Heater Core Replacement . Disconnect any wiring connectors. Invert the auxiliary HVAC module to access components.
1Auxiliary A/C Evaporator and Blower Lower Case - Outboard Screw (Qty: 12) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
2Auxiliary A/C Evaporator and Blower Lower Case - Outboard Procedure Note the location and routing of the wiring harness to ensure proper reinstallation. When replacing the HVAC case, transfer all necessary components.
NOTE
Refer to Fastener Notice .

Scheme 16

Scheme 16: Auxiliary Air Conditioning Evaporator and Blower Lower Case Replacement
Scheme 16: Auxiliary Air Conditioning Evaporator and Blower Lower Case Replacement
CalloutComponent Name
Preliminary Procedure Remove the auxiliary heater core. Refer to Auxiliary Heater Core Replacement . Disconnect any wiring connectors. Invert the auxiliary HVAC module to access components.
1Auxiliary A/C Evaporator and Blower Lower Case Screw (Qty: 10) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
2Auxiliary A/C Evaporator and Blower Lower Case
NOTE
Refer to Fastener Notice .

Scheme 17

Scheme 17: Auxiliary Air Conditioning Evaporator Tube Replacement
Scheme 17: Auxiliary Air Conditioning Evaporator Tube Replacement
CalloutComponent Name
Preliminary Procedure Remove the auxiliary evaporator core. Refer to Auxiliary Air Conditioning Evaporator Replacement . Disconnect any wiring connectors.
1Auxiliary A/C Evaporator Outlet Tube Bolt NOTE: Refer to Fastener Notice . Tighten: 4 N.m (35 lb in)
2Auxiliary A/C Evaporator Outlet Tube Tip: Ensure new O-rings are used upon installation.
NOTE
Refer to Fastener Notice .
  1. Recover the refrigerant from the system. Refer to «Refrigerant Recovery and Recharging»(ref-299130-S36373810622008092200000) .
  2. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-299142-S39860654132008092200000) .
  3. Remove the auxiliary evaporator hose nuts (1) from the main evaporative hose connections.
  4. Separate auxiliary evaporator hoses (3) and O-rings (2).
  5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299137-S12533882312008092200000) .
  6. Remove the right assist step if necessary. Refer to «Assist Step Replacement (w/WS2, BVX)»(ref-299135-S18096453502008092200000) or «Assist Step Replacement (Tubular BVE)»(ref-299135-S20242574652008092200000) .
  7. Remove the front wheelhouse liner if necessary. Refer to «Wheelhouse Panel Replacement»(ref-299135-S07316607702008092200000) .
  8. Remove the auxiliary A/C tubes connector nuts (1) from the intermediate connection point.
  9. Remove the auxiliary A/C tubes clip push pins (1) from vehicle frame locations.
  10. Remove the auxiliary A/C tubes (2) from vehicle.
  11. Remove auxiliary A/C tubes clip retaining push pin/bolt (1) if necessary.
  12. Use a flat-bladed release tool to open retaining clips (2).
  13. Remove auxiliary A/C tubes from vehicle.
IMPORTANTThe replacement A/C and heater pipes are shipped in front and rear sections.
  1. Install the auxiliary A/C evaporator tubes (3) to the retaining clips (2).
  2. Install the auxiliary A/C evaporator tubes (3) to the vehicle.
  3. Install the auxiliary A/C tubes clip push pins (1) to vehicle frame locations.
  4. Install new O-rings with replacement auxiliary A/C tubes. Refer to «O-Ring Replacement»(ref-299130-S01637741562008092200000) .
  5. Install the auxiliary A/C tube connection nuts (1) to the intermediate connection point. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
  6. Install the right assist step if necessary. Refer to «Assist Step Replacement (w/WS2, BVX)»(ref-299135-S18096453502008092200000) or «Assist Step Replacement (Tubular BVE)»(ref-299135-S20242574652008092200000) .
  7. Lower the vehicle.
  8. Install new O-rings with replacement auxiliary A/C tubes. Refer to «O-Ring Replacement»(ref-299130-S01637741562008092200000) .
  9. Install the auxiliary evaporator hose nuts (1) to the main evaporative hose connections. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
  10. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-299142-S39860654132008092200000) .
  11. Recharge the refrigerant to the system. Refer to «Refrigerant Recovery and Recharging»(ref-299130-S36373810622008092200000) .
  12. Leak test the fittings of the component using the J 39400-A .
  1. Recover the refrigerant from the system. Refer to «Refrigerant Recovery and Recharging»(ref-299130-S36373810622008092200000) .
  2. Drain the engine coolant if necessary. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .
  3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299137-S12533882312008092200000) .
  4. Remove the right assist step if necessary. Refer to «Assist Step Replacement (w/WS2, BVX)»(ref-299135-S18096453502008092200000) or «Assist Step Replacement (Tubular BVE)»(ref-299135-S20242574652008092200000) .
  5. Remove the rear wheelhouse liner. Refer to «Wheelhouse Panel Replacement»(ref-299135-S07316607702008092200000) .
  6. Remove the auxiliary A/C evaporator tubes connector nuts (1) from the intermediate connection point.
  7. Remove the auxiliary heater tubes connector nuts (2) if necessary.
  8. Remove the retaining nut (1) and the auxiliary A/C evaporator tubes (3) from the auxiliary HVAC module.
  9. Remove the heater - A/C tubes retaining push pins (1) at the frame locations.
  10. Remove the heater - A/C tubes retaining bolt (2) at the frame location.
  11. Remove the auxiliary A/C evaporator tubes (3) from the frame.
  12. Remove the auxiliary A/C evaporator tubes from the vehicle.
  13. Remove auxiliary heater - A/C tubes clip retaining push pin/bolt (1) if necessary.
  14. Use a flat-bladed release tool to open retaining clips (2).
  15. Remove auxiliary A/C tubes from vehicle.
IMPORTANTThe replacement A/C and heater pipes are shipped in front and rear sections.
  1. Install the auxiliary A/C evaporator tubes (3) to the retaining clips (2).
  2. Install the auxiliary A/C evaporator tubes (3) to the vehicle.
  3. Install the auxiliary heater - A/C tube nut (2). Tighten: Tighten the nut to 7 N.m (62 lb in).
  4. Install the auxiliary heater - A/C tube push pins (1).
  5. Install the auxiliary heater - A/C tubes (3) and the retaining nuts (1) to the auxiliary HVAC module. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  6. Install new O-rings with replacement auxiliary A/C tubes. Refer to «O-Ring Replacement»(ref-299130-S01637741562008092200000) .
  7. Install new O-rings with replacement auxiliary A/C tubes. Refer to «O-Ring Replacement»(ref-299130-S01637741562008092200000) .
  8. Install the auxiliary heater - A/C tube connection nuts (1) to the intermediate connection point. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
  9. Install the auxiliary heater tubes connector nuts (2) if necessary. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
  10. Install the rear wheelhouse liner. Refer to «Wheelhouse Panel Replacement»(ref-299135-S07316607702008092200000) .
  11. Install the right assist step if necessary. Refer to «Assist Step Replacement (w/WS2, BVX)»(ref-299135-S18096453502008092200000) or «Assist Step Replacement (Tubular BVE)»(ref-299135-S20242574652008092200000) .
  12. Lower the vehicle.
  13. Fill the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-299178-S18372770872008092200000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-299178-S18875031892008092200000) .
  14. Recharge the refrigerant to the system. Refer to «Refrigerant Recovery and Recharging»(ref-299130-S36373810622008092200000) .
  15. Leak test the fittings of the component using the J 39400-A .

More articles — Heating, Ventilation, and Air Conditioning