HVAC Control System: Removal & Installation Mercury Mariner II

REMOVAL AND INSTALLATION

Note. Installation of a new receiver/drier is not required when repairing the A/C system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the receiver/drier.

Note. If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
3. Remove the RH lower engine splash shield.
4. Release the tensioner and remove the drive belt from the A/C compressor pulley.
5. Disconnect the A/C clutch field coil electrical connector.
6. Remove the 3 A/C compressor bolts and lower the A/C compressor to allow access to the suction and discharge fitting nuts. To install, tighten the A/C compressor bolts to 25 Nm (18 lb-ft).
7. Remove the A/C compressor suction and discharge fitting nuts and disconnect the fittings. Discard the O-ring seals and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
8. Remove the A/C compressor.
9. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit. For additional information, refer to «Clutch and Clutch Field Coil - 2.3L, 3.0L (4V)»(ref-292181-S31748978552008073100000) . If not filtering the A/C system, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the A/C system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the receiver/drier.

Note. If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
3. Remove the RH lower engine splash shield.
4. Release the tensioner and remove the drive belt from the A/C compressor pulley.
5. Remove the A/C compressor suction and discharge fitting nuts and disconnect the fittings. Discard the O-ring seals and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
6. Disconnect the A/C clutch field coil electrical connector.
7. Remove the 3 A/C compressor bolts. To install, tighten to 25 Nm (18 lb-ft).
8. Remove the A/C compressor.
9. To install, reverse the removal procedure. If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit. For additional information, refer to «Clutch and Clutch Field Coil - 2.3L, 3.0L (4V)»(ref-292181-S31748978552008073100000) . Install new gasket seals and O-ring seals. If not filtering the A/C system, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

1. Lower the glove compartment.
2. Detach the instrument panel wire harness pin-type retainer and position the wire harness away from the evaporator discharge air temperature sensor.
3. Disconnect the A/C evaporator discharge air temperature sensor electrical connector.
4. Gently pry upward and remove the A/C evaporator discharge air temperature sensor.
5. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
3. Remove the A/C pressure relief valve and O-ring seal. To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure. Add the correct amount of clean PAG refrigerant oil to the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
5. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Scheme 140

1. Detach the ambient air temperature sensor electrical connector from the bumper.
2. Disconnect and remove the ambient air temperature sensor.
3. To install, reverse the removal procedure.

Scheme 141

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-292201) article.
3. Remove the LH lower engine splash shield.
4. Release the clamp and disconnect the auxiliary coolant pump-to-thermostat hose.
5. Release the clamp and disconnect the heater outlet hose.
6. Disconnect the auxiliary coolant flow pump electrical connector.
7. Remove the 2 auxiliary coolant flow pump bolts. To install, tighten to 4 Nm (35 lb-in).
8. Remove the auxiliary coolant flow pump and rubber bracket assembly.
9. To install, reverse the removal procedure. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-292201) article.

Scheme 142

1. Disconnect the blower motor electrical connector.
2. Release the 2 blower motor vent tube clips and pull the vent tube down until it is disengaged from the heater core and evaporator core housing.
3. Rotate the blower motor counterclockwise to disengage it from the housing and remove the blower motor.
4. To install, reverse the removal procedure.

Scheme 143

1. Lower the glove compartment.
2. Disconnect the blower motor resistor electrical connector.
3. Remove the 2 blower motor resistor screws. To install, tighten to 3 Nm (27 lb-in).
4. Remove the blower motor resistor.
5. To install, reverse the removal procedure.

Scheme 144

1. Lower the glove compartment.
2. Disconnect the blower motor speed control electrical connector.
3. Remove the 2 blower motor speed control screws. To install, tighten to 3 Nm (27 lb-in).
4. Remove the blower motor speed control.
5. To install, reverse the removal procedure.

REMOVAL

1. Remove the A/C compressor. For additional information, refer to «Air Conditioning (A/C) Compressor - 2.3L»(ref-292181-S42897743002008073100000) or «Air Conditioning (A/C) Compressor - 3.0L (4V)»(ref-292181-S08553157972008073100000) .
2. Remove the A/C clutch disc and hub bolt. Using a suitable spanner-type wrench, hold the A/C clutch disc and hub. Remove the A/C clutch disc and hub bolt.
3. Remove the A/C clutch disc and hub and the A/C clutch disc and hub spacer(s).
4. Remove the A/C compressor pulley snap ring.
5. Remove the A/C compressor pulley. Install the special tool. Install a suitable 3-jaw puller on the special tool and A/C compressor pulley. Remove the A/C compressor pulley.
6. Remove the 4 A/C clutch field coil screws.
7. Remove the A/C clutch field coil.

INSTALLATION

Note. The A/C clutch components should be reused unless obvious signs of damage are found.

1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C clutch field coil and pulley mounting surfaces.
3. Install the A/C clutch field coil.
4. Install the 4 A/C clutch field coil screws.
5. Install the A/C compressor pulley. Install the A/C compressor on a suitable press. Position the A/C compressor pulley on the A/C compressor. Install the special tool on the A/C compressor pulley. Using the press, install the A/C compressor pulley.
6. Install the A/C compressor pulley snap ring with the bevel side out.
7. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
8. Install the A/C clutch disc and hub.
9. Install the A/C compressor clutch disc and hub bolt. Hold the A/C clutch disc and hub with a suitable spanner-type wrench. Tighten the bolt to 20 Nm (15 lb-ft).
10. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers.
11. Install the A/C compressor. For additional information, refer to «Air Conditioning (A/C) Compressor - 2.3L»(ref-292181-S42897743002008073100000) or «Air Conditioning (A/C) Compressor - 3.0L (4V)»(ref-292181-S08553157972008073100000) .

1. Remove the A/C compressor. For additional information, refer to «Air Conditioning (A/C) Compressor - Hybrid»(ref-292181-S13329933032008073100000) .
2. Remove the A/C clutch disc and hub nut. Using the special tool, hold the A/C clutch disc and hub. Remove the A/C clutch disc and hub nut.
3. Remove the A/C clutch disc and hub.
4. Remove the A/C compressor pulley snap ring.
5. Using the special tool, remove the A/C compressor pulley.
6. Remove the A/C clutch field coil snap ring.
7. Remove the A/C clutch field coil. Remove the thermal protection switch bolt and bracket. Detach the thermal protection switch from the A/C compressor.
8. Remove the A/C clutch field coil and thermal protection switch assembly.

Note. NOTE: The A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and a new A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed.

1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C clutch field coil and pulley mounting surfaces.
3. Apply a pea-sized drop of silicone sealant to the thermal protection switch socket in the A/C compressor housing.
4. Install the A/C clutch field coil. Install the A/C clutch field coil. Install the thermal protection switch and bracket. Tighten the thermal protection switch bolt to 6 Nm (53 lb-in).
5. Install the A/C compressor pulley. Install the special tool. Install the A/C compressor pulley.
6. Install the A/C compressor pulley snap ring with the bevel side out.
7. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
8. Install the A/C clutch disc and hub.
9. Using the special tool, install the A/C compressor clutch disc and hub nut. Hold the A/C clutch disc and hub with the special tool. Tighten the nut to 26 Nm (19 lb-ft).
10. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers.
11. Install the A/C compressor. For additional information, refer to «Air Conditioning (A/C) Compressor - Hybrid»(ref-292181-S13329933032008073100000) .

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
3. Remove the DC/DC converter. For additional information, refer to «HIGH VOLTAGE CONVERTER/INVERTER»(ref-292219) article.
4. Remove the front bumper cover. For additional information, refer to «BUMPERS»(ref-292171) article.
5. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 15 Nm (11 lb-ft).
6. Remove the A/C compressor manifold bolt and disconnect the compressor manifold and tube from the A/C compressor. Discard the O-ring seals. To install, tighten to 20 Nm (15 lb-ft).
7. Remove the 2 evaporator outlet line fitting nuts. Discard the O-ring seals and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
8. Remove the compressor manifold and tube assembly bracket nut. To install, tighten to 8 Nm (71 lb-in).
9. Remove the compressor manifold and tube assembly.
10. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
11. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
3. Remove the RH lower engine splash shield.
4. Remove the front bumper cover. For additional information, refer to «BUMPERS»(ref-292171) article.
5. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
6. Remove the A/C compressor discharge fitting nut and disconnect the fitting. Discard the O-ring and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
7. Remove the compressor-to-condenser discharge line.
8. To install, reverse the removal procedure. Install new gasket and O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Recover refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
3. Remove the RH lower engine splash shield.
4. Remove the front bumper cover. For additional information, refer to «BUMPERS»(ref-292171) article.
5. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
6. Remove the A/C compressor discharge fitting nut and disconnect the fitting. Discard the O-ring and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
7. Remove the compressor-to-condenser discharge line.
8. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

Note. If a condenser core leak is suspected, the condenser core must be leak tested before it is removed from the vehicle. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
3. Remove the front bumper cover. For additional information, refer to «BUMPERS»(ref-292171) article.
4. Remove the 4 radiator bracket bolts. To install, tighten to 8 Nm (71 lb-in).
5. Detach and remove the RH and LH radiator brackets.
6. Remove the condenser outlet and inlet fitting nuts and disconnect the fittings. Discard the O-ring and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
7. Release the 2 transmission cooler line clamps and disconnect the lines from the A/C condenser.
8. Remove the 2 condenser bolts. To install, tighten to 7 Nm (62 lb-in).
9. Remove the condenser core.
10. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
11. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

Note. If a condenser core leak is suspected, the condenser core must be leak tested before it is removed from the vehicle. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
3. Remove the motor electronics cooler. For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING - HYBRID»(ref-292220) article.
4. Remove the 4 radiator bracket bolts. To install, tighten to 8 Nm (71 lb-in).
5. Detach and remove the RH and LH radiator brackets.
6. Remove the condenser outlet and inlet fitting nuts and disconnect the fittings. Discard the O-ring seals. To install, tighten to 15 Nm (11 lb-ft).
7. Remove the 2 condenser bolts. To install, tighten to 7 Nm (62 lb-in).
8. Remove the condenser core.
9. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
2. Remove the DC/DC converter. For additional information, refer to «HIGH VOLTAGE CONVERTER/INVERTER»(ref-292219) article.
3. Remove the front bumper cover. For additional information, refer to «BUMPERS»(ref-292171) article.
4. Remove the compressor manifold and tube bracket nut. To install, tighten to 8 Nm (71 lb-in).
5. Remove the condenser outlet fitting nut and disconnect the fitting. Discard the O-ring seal.
6. Remove the evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
7. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
8. Remove the receiver/drier inlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
9. Remove the condenser-to-receiver/drier line.
10. To install, reverse the removal procedure. Install new gasket seal and O-ring seal. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
11. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
2. Remove the evaporator inlet line bracket nut. To install, tighten to 8 Nm (71 lb-in).
3. Remove the receiver/drier outlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
4. Remove the thermostatic expansion valve (TXV) fitting nut and disconnect the fitting. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
5. Remove the evaporator inlet line.
6. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
7. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
2. Remove the evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
3. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
4. Disconnect the low-charge protection switch electrical connector.
5. Remove the thermostatic expansion valve (TXV) fitting nut and disconnect the fitting. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
6. Remove the passenger zone valve nut. To install, tighten to 7 Nm (62 lb-in).
7. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 Nm (71 lb-in).
8. Remove the receiver/drier outlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
9. Disconnect the passenger zone valve electrical connector.
10. Detach the evaporator inlet line from the A/C line bracket.
11. Remove the evaporator inlet line.
12. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
13. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
3. Remove the RH lower engine splash shield.
4. Remove the A/C compressor suction fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
5. Detach the wire harness clip from the evaporator outlet line.
6. Remove the thermostatic expansion valve (TXV) fitting nut and disconnect the fitting. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
7. Disconnect the low-charge protection switch electrical connector.
8. Detach the evaporator outlet line from the receiver/drier bracket.
9. Remove the evaporator outlet line.
10. To install, reverse the removal procedure. Install new gasket seals and a new O-ring seal. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
11. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
2. Disconnect the low-charge protection switch electrical connector.
3. Remove the evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
4. Remove the thermostatic expansion valve (TXV) fitting nut and disconnect the fitting. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
5. Detach the evaporator outlet line from the A/C line bracket.
6. Remove the evaporator outlet line.
7. To install, reverse the removal procedure. Install a new O-ring and new gasket seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Scheme 145

All vehicles

1. Remove the driver and front passenger seats. For additional information, refer to «SEATING»(ref-292177) article.
2. Remove the floor console. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-292175) article.
3. Remove the front door scuff plate trim panels and the lower A-pillar trim panels. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-292173) article.
4. Detach the selector lever cable from the gearshift assembly. Disconnect the selector lever cable end from the gearshift lever. Remove the selector lever cable from the bracket.
5. Separate the wiring harness from the LH floor duct and position aside.
6. Remove the LH floor duct.
7. Remove the RH floor duct pin-type retainer.
8. Remove the RH floor duct.
9. To install, reverse the removal procedure.

Scheme 146

Note. If a heater core leak is suspected, the heater core must be leak tested before the heater core is removed. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.

Note. Use only the approved coolant for this vehicle. For additional information, refer to ENGINE COOLING article or ENGINE COOLING - HYBRID article.

1. Remove the heater core and evaporator core housing. For additional information, refer to «Heater Core And Evaporator Core Housing»(ref-292181-S41641367162008073100000) .
2. Remove the dash panel seal.
3. Remove the heater core bracket screw and the heater core bracket. To install, tighten to 3 Nm (27 lb-in).
4. Remove the heater core.
5. To install, reverse the removal procedure.

Note. If a heater core leak is suspected, the heater core must be leak tested before the heater core is removed. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.

1. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-292200) article or «ENGINE COOLING - HYBRID»(ref-292201) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
3. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-292175) article.
4. Remove the thermostatic expansion valve (TXV) fitting nut and disconnect the fitting. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
5. Release the clamps and disconnect the heater inlet and outlet hoses from the heater core.
6. Remove the 6 heater core and evaporator core housing nuts. To install, tighten to 9 Nm (80 lb-in).
7. Remove the heater core and evaporator core housing. Detach the heater core and evaporator core housing from the dash panel studs. Rotate the RH side of the heater core and evaporator core housing toward the rear of the vehicle while pulling the housing toward the RH door opening to detach it from the rear footwell duct. Remove the heater core and evaporator core housing.
8. Disassemble the heater core and evaporator core housing as needed.
9. To install, reverse the removal procedure. Install new gasket seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
10. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-292200) article or «ENGINE COOLING - HYBRID»(ref-292201) article.
11. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Scheme 147

1. Remove the center instrument panel finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-292175) article.
2. Remove the 4 HVAC module screws.
3. Remove the HVAC module.
4. To install, reverse the removal procedure.

In-Vehicle Temperature and Humidity Sensor

Note. In-vehicle temperature and humidity sensor shown. In-vehicle temperature sensor similar.

Scheme 148

1. Detach the instrument cluster finish panel and position it away from the instrument panel to allow access to the in-vehicle temperature sensor.
2. Release the 2 clips and detach the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor.
3. Disconnect the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor electrical connector.
4. Detach the aspirator hose from the venturi at the heater core and evaporator core housing.
5. Detach the aspirator hose from the instrument panel.
6. Remove the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor.
7. Remove the venturi (if needed).
8. To install, reverse the removal procedure.

Scheme 149

1. Remove the heater core and evaporator core housing. For additional information, refer to «Heater Core And Evaporator Core Housing»(ref-292181-S41641367162008073100000) .
2. Disconnect the air inlet mode door actuator electrical connector.
3. Remove the 2 air inlet mode door actuator screws. To install, tighten to 3 Nm (27 lb-in).
4. Remove the air inlet mode door actuator.
5. To install, reverse the removal procedure.

Scheme 150

Note. The defrost/panel/floor mode door actuator can be accessed from below the LH side of the instrument panel.

1. Disconnect the defrost/panel/floor mode door actuator electrical connector.
2. Remove the 2 defrost/panel/floor mode door actuator screws. To install, tighten to 3 Nm (27 lb-in).
3. Remove the defrost/panel/floor mode door actuator.
4. To install, reverse the removal procedure.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
2. Disconnect the passenger zone valve electrical connector.
3. Disconnect the 2 passenger zone valve fittings. Discard the O-ring seals. To install, tighten to 17 Nm (13 lb-ft).
4. Remove the passenger zone valve bracket nut. To install, tighten to 7 Nm (62 lb-in).
5. Remove the passenger zone valve.
6. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
7. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. The receiver/drier fitting studs can be removed and installed separately from the receiver/drier and are available as service parts. If only the fitting studs are damaged, it is not necessary to install a new receiver/drier.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
2. Remove the front bumper cover. For additional information, refer to «BUMPERS»(ref-292171) article.
3. Remove the condenser outlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
4. Disconnect the dual-function pressure switch electrical connector.
5. Remove the receiver/drier outlet fitting nut and disconnect the fitting. To install, tighten to 15 Nm (11 lb-ft). Discard the O-ring seal and gasket seal.
6. Detach the evaporator outlet line from the receiver/drier bracket clip.
7. Remove the 2 receiver/drier nuts. To install, tighten to 8 Nm (71 lb-in).
8. Remove the receiver/drier.
9. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

Note. The receiver/drier fitting studs can be removed and installed separately from the receiver/drier and are available as service parts. If only the fitting studs are damaged, it is not necessary to install a new receiver/drier.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
2. Remove the evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
3. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
4. Remove the passenger zone valve bracket nut. To install, tighten to 7 Nm (62 lb-in).
5. Disconnect the dual-function pressure switch electrical connector and detach the wire harness from the receiver/drier bracket stud.
6. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 Nm (71 lb-in).
7. Remove the receiver/drier inlet and outlet fitting nuts and disconnect the outlet fitting. Discard the outlet fitting O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
8. Remove the 2 receiver/drier nuts and disconnect the receiver/drier inlet fitting. Discard the O-ring seal and gasket seal. To install, tighten to 7 Nm (62 lb-in).
9. Remove the receiver/drier.
10. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
11. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

1. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-292175) article.

Scheme 151

1. Using a suitable tool, gently pry to disengage the register clips from the instrument panel while working around the perimeter of the register.
2. Remove the driver side register.
3. To install, reverse the removal procedure.

Scheme 152

1. Using a suitable tool, gently pry to disengage the register clips from the instrument panel while working around the perimeter of the register.
2. Remove the passenger side register.
3. To install, reverse the removal procedure.

Scheme 153

Note. The LH temperature blend door actuator is present on dual-zone electronic automatic temperature control (EATC) vehicles to control the LH temperature blend door only. Vehicles equipped with electronic manual temperature control (EMTC) are not equipped with this actuator. For EMTC vehicles, refer to Temperature Blend Door Actuator - RH .

1. Disconnect the LH temperature blend door actuator electrical connector.
2. Remove the 2 LH temperature blend door actuator screws. To install, tighten to 3 Nm (27 lb-in).
3. Remove the LH temperature blend door actuator.
4. To install, reverse the removal procedure.

Scheme 154

Note. On vehicles equipped with dual-zone electronic automatic temperature control (EATC), the RH temperature blend door actuator is used to control only the RH temperature blend door. On vehicles equipped with electronic manual temperature control (EMTC), the RH temperature blend door actuator is used to control the single temperature blend door for both sides of the vehicle.

1. Remove the upper center instrument panel finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-292175) article.
2. Remove the passenger airbag module. For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-292178) article.
3. Working through the passenger airbag module opening, remove the RH panel duct screw.
4. Working through the passenger airbag module opening, remove the upper RH center panel duct screw
5. Remove the lower RH center panel duct screw. Detach the wire harness pin-type retainer. Remove the lower RH center panel duct screw.
6. Working through the glove compartment opening, detach the wire harness pin-type retainer above the evaporator discharge air temperature sensor.
7. Disconnect the RH temperature blend door actuator electrical connector.
8. Remove the 2 RH temperature blend door actuator screws. To install, tighten to 3 Nm (27 lb-in).
9. Remove the RH temperature blend door actuator.
10. To install, reverse the removal procedure.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.
2. Remove the thermostatic expansion valve (TXV) fitting nut and disconnect the fitting. Discard the gasket seals.
3. Remove the 2 TXV bolts and the TXV. Discard the O-ring seals.
4. To install, reverse the reverse the removal procedure. If the TXV stud has become loose during removal, or has been removed for any reason, tighten the TXV stud to 6 Nm (53 lb-in) before the TXV fitting nut is reinstalled. Install new O-ring seals and gasket seals.
5. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-292158) article.

Scheme 155

Scheme 156