HVAC System - Automatic - Aurora: Removal & Installation Oldsmobile Aurora II

REMOVAL & INSTALLATION

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect orifice solenoid wiring harness. Remove accumulator cover. Remove A/C suction hose from accumulator. Remove evaporator hose from accumulator. Remove accumulator form housing. To install reverse removal procedure. Add 2.0 ounces of refrigerant oil to replacement accumulator.

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect A/C low side temperature sensor harness connector. Unscrew A/C low side temperature sensor from refrigerant line and remove sensor. To install, reverse removal procedure. Lubricate "O" ring with refrigerant oil.

Raise and support vehicle. Remove 13 retainers from front air deflector and remove front air deflector. (Scheme 4) Disconnect harness connector from A/C refrigerant pressure sensor and remove sensor. To install, reverse removal procedure. Lubricate "O" ring with refrigerant oil.

Scheme 4

Scheme 5

1. Remove 2 screws securing lower dashboard insulator panel to instrument panel retainer. Remove air temperature sensor from closeout insulator panel by turning it 1/4 turn counterclockwise. Disconnect harness connector from lower instrument panel courtesy light. Slide lower dashboard insulator panel to rear in order to remove it from vehicle. Gently pry out on rear edge of instrument panel outer trim cover until retainers securing outer trim cover to instrument panel release from retainer.
2. Slide instrument panel radio trim cover toward rear until tabs on front edge of outer trim cover disengage from instrument panel retainer. (Scheme 5) Remove knee bolster, by pulling past holding tab and lifting up. Unsnap knee bolster by pulling down and to rear and remove from vehicle.
3. Remove Instrument Panel Module (IPM) bolt and wiring harness connector. Remove harness connector from left air temperature door actuator. Remove left air temperature door actuator 2 retaining screws and remove left air temperature door actuator. To install reverse installation procedure.

Removal & Installation (Right)

Remove 4 screws that hold glove box door to instrument panel. Pull on glove box door toward rear and remove door. Remove fasteners that secure glove box door to glove box. Remove retaining screw and harness connector from right air temperature door actuator and remove actuator. see scheme 4 To install, reverse removal procedure.

Removal & Installation (Right & Left)

Remove HVAC head. See HVAC CONTROL HEAD . Remove mode actuator. See MODE ACTUATOR . Remove recirculation actuator. See RECIRCULATION ACTUATOR . Remove right and left air temperature mode actuators. See AIR TEMPERATURE DOOR ACTUATORS . Remove mode actuator bracket fasteners and bracket. Remove upper module case fasteners. Peel back foam from heater inlet and remove upper case. Remove right or left temperature door. To install, reverse removal procedure.

Removal & Installation (Lower Left Sensor)

Remove 2 screws securing lower dashboard insulator panel to instrument panel retainer. Remove air temperature sensor from closeout insulator panel by turning it 1/4 turn counterclockwise. Disconnect harness connector from lower instrument panel courtesy light. Slide lower dashboard insulator panel to rear in order to remove it from vehicle. Remove harness connector from air temperature sensor and remove sensor. To install, reverse removal procedure.

Removal & Installation (Lower Right Sensor)

Remove fasteners and push in retainers, holding lower dashboard insulator panel to dashboard. Turn air temperature sensor 1/4 turn counterclockwise to remove from insulator panel. Disconnect harness connector from lower instrument panel courtesy light. Slide insulator panel to rear and remove from vehicle. Disconnect harness connector from sensor. To install, reverse removal procedure.

Removal & Installation (Upper Left & Right Sensors)

Gently pry out on rear edge of instrument panel outer trim cover until retainers securing outer trim cover to instrument panel release from retainer. Slide instrument panel radio trim cover toward rear until tabs on front edge of outer trim cover disengage from instrument panel retainer. (Scheme 5) Remove upper air temperature sensor by twisting 1/4 turn. Disconnect harness connector and remove sensor. To install, reverse removal procedure.

Disconnect harness connector from ambient air temperature sensor, located below hood latch. Remove retainer and ambient air temperature sensor. To install, reverse removal procedure.

Remove 2 screws securing lower dashboard insulator panel to instrument panel retainer. Remove air temperature sensor from closeout insulator panel by turning it 1/4 turn counterclockwise. Disconnect harness connector from lower instrument panel courtesy light. Slide lower dashboard insulator panel to rear in order to remove it from vehicle. Remove aspirator hose at muffler. Remove aspirator mounting bolt and use a tool with a flat blade to remove it from HVAC case. To install, reverse removal procedure.

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Disconnect negative battery cable. Remove fasteners and push in retainers, holding lower dashboard insulator panel to dashboard. Turn air temperature sensor 1/4 turn counterclockwise to remove from insulator panel. Disconnect harness connector from lower instrument panel courtesy light. Slide insulator panel to rear and remove from vehicle.
2. Pull carpet back near blower motor. Remove 4 screws that hold glove box door to instrument panel. Pull toward rear on glove box door and remove door. Remove fasteners that secure glove box door to glove box. Remove Dashboard Integration Module (DIM) from bracket and position to side. Remove rear DIM bracket screws and lower bracket far enough to gain access to blower motor.
3. Disconnect harness connector from blower motor. Remove 6 blower motor retaining screws. Lower blower motor and rotate it clockwise to remove it from vehicle. To install, reverse removal procedure.

1. Remove fasteners and push in retainers, holding left lower dashboard insulator panel to dashboard. Turn air temperature sensor 1/4 turn counterclockwise to remove from insulator panel. Disconnect harness connector from lower instrument panel courtesy light. Slide insulator panel to rear and remove from vehicle.
2. Remove 4 screws that hold glove box door to instrument panel. Pull toward rear on glove box door and remove door. Remove fasteners that secure glove box door to glove box. Remove Dashboard Integration Module (DIM) from bracket and position to side. Remove rear DIM bracket screws and lower bracket far enough to gain access to blower motor control processor.
3. Disconnect blower motor control processor harness connector. Remove processor retaining screws and remove processor. To install, reverse removal procedure.

1. Pull instrument panel radio trim plate to rear and disengage clips and remove trim plate. Remove 2 screws for console trim plate from just below radio. Pull up on rear of trim plate to disengage retaining clips. Disconnect harness connectors and remove console trim plate. Remove screws from console compartment tray and pull to rear. Disconnect harness connector from cigarette lighter. Remove left and right console side trim panels by sliding them to rear of vehicle to disengage clips. Remove shifter cable. Remove shift park/lock cable.
2. Remove main wiring harness connector from console. Open glove box and remove console bolt. Remove bolt from left side of console and 2 nuts from just above radio. Remove 2 screws going into floor at about middle of console. Move front seats forward and remove 2 screws from each side of console at rear. Carefully slide console to rear and lift up to remove from vehicle. To install, reverse removal procedure.

Removal & Installation (3.5L Engine)

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect negative battery cable. Remove drive belt. Raise and support vehicle. Remove right front wheel. Remove 13 fasteners and remove front air deflector. (Scheme 4) Remove 5 retainers for right front inner fender panel. Support front of engine cradle with a floor jack. Remove right front engine cradle bolt and lower cradle. Remove drive belt idler pulley.
2. Disconnect suction and discharge hoses from compressor. Remove generator mounting bolts and position generator out of way. Disconnect harness connector from compressor. Remove 2 upper compressor mounting bolts. Position generator and temporarily install idler pulley to hold generator out of the way. Loosen rear compressor mounting nut and remove front mounting nut. Remove compressor from engine block. Rotate compressor to allow compressor to exit through wheelwell opening and remove compressor from vehicle.
3. Measure amount of oil drained from compressor. Fill replacement compressor with 2.7 ounces of oil. If amount drained is more than amount specified, add amount drained. Reverse removal procedure and recharge A/C system. See «TORQUE SPECIFICATIONS»(ref-91547-S00088731082001032600000).

Removal & Installation (4.0L Engine)

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove drive belt. Raise and support vehicle. Remove right front wheel. Remove 13 fasteners and remove front air deflector. (Scheme 4) Remove 5 retainers for right front inner fender panel. Disconnect washer hose form washer pump. Disconnect harness connector from washer pump. Disconnect harness connector from washer liquid level sensor. Remove 3 nuts from washer bottle and remove bottle. Remove right front brake line retainer clips from frame to allow brake lines to move. Disconnect suction and discharge hoses from compressor.
2. Disconnect harness connector from compressor. Remove 2 rear compressor mounting bolts. Remove lower generator mounting bolt. Remove compressor front mounting bolt. Remove compressor mounting stud. Rotate compressor to allow it to be removed from through wheelwell opening.
3. Drain and measure old compressor oil. To install, reverse removal procedure. Fill replacement compressor with 2.7 ounces of oil. If amount drained is more than amount specified, add amount drained. Charge A/C system. See «TORQUE SPECIFICATIONS»(ref-91547-S00088731082001032600000).

Scheme 6

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove upper tie bar support brace. Loosen support brace bolts from headlight and bumper trim mounting panel and position out of way. Remove upper radiator seal. Remove upper radiator mounting brackets. Disconnect compressor discharge hose from condenser.
2. Remove both headlights, by removing 2 upper headlight retaining screws. Carefully pry in center of headlight with a pry bar straight forward to unsnap ball stud from its socket. (Scheme 6) Move headlight forward and disconnect it from its wiring harness and remove headlights from vehicle.
3. Disconnect evaporator hose from condenser. Remove one bolt and one fastener from each side of headlight and bumper trim mounting panel. Lift headlight and bumper fascia mounting panel and pull forward to obtain access for condenser removal. Remove 2 condenser to radiator mounting bolts. Separate condenser from radiator by lifting out of lower mounting tabs. Remove 2 condenser seals. Lift condenser and remove from vehicle.
4. Measure amount of oil drained from condenser. To install, reverse removal procedure. Fill replacement condenser with one ounce of refrigerant oil. If amount drained is more than amount specified, add amount drained.

Remove HVAC head. See HVAC CONTROL HEAD . Remove mode actuator. See MODE ACTUATOR . Remove recirculation actuator. See RECIRCULATION ACTUATOR . Remove left air temperature mode actuators. See AIR TEMPERATURE DOOR ACTUATORS . Remove fasteners which mode actuator bracket. Remove upper module case fasteners. Peel back foam from heater inlet and remove upper case. Remove right or left temperature door. To install reverse removal procedure. Remove actuator cam from defroster door and remove door. To install, reverse removal procedure.

Before replacing DIM, record personalization settings to transfer to new module (if they are available). Replacement DIM must be reprogrammed. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT. Remove 2 screws securing lower dashboard insulator panel to instrument panel retainer. Remove air temperature sensor from closeout insulator panel by turning it 1/4 turn counterclockwise. Disconnect harness connector from lower instrument panel courtesy light. Slide lower dashboard insulator panel to rear in order to remove it from vehicle. Release tab from behind module and remove module from retainer. Disconnect harness connector and remove module from vehicle. To install, reverse removal procedure.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove HVAC head. See «HVAC CONTROL HEAD»(ref-91547-S17636773612001032600000) . Remove mode actuator. See «MODE ACTUATOR»(ref-91547-S08547292932001032600000) . Remove recirculation actuator. See «RECIRCULATION ACTUATOR»(ref-91547-S40901149452001042400000) . Remove right and left air temperature door actuators. See «AIR TEMPERATURE DOOR ACTUATORS»(ref-91547-S20118032202001042400000) .
2. Remove mode actuator bracket fasteners and bracket. Remove upper module case fasteners. Peel back foam from heater inlet and remove upper case. Remove evaporator core and measure amount of oil in unit. To install, reverse removal procedure Fill replacement condenser with 3.0 ounces of refrigerant oil. If amount drained is more than amount specified, add amount drained. Charge A/C system.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain cooling system. Remove both heater hoses from heater core. Remove 2 screws securing lower dashboard insulator panel to instrument panel retainer. Remove air temperature sensor from closeout insulator panel by turning it 1/4 turn counterclockwise.
2. Disconnect harness connector from lower instrument panel courtesy light. Slide lower dashboard insulator panel to rear in order to remove it from vehicle. Remove fasteners and push in retainers, holding lower dashboard insulator panel to dashboard. Turn air temperature sensor 1/4 turn counterclockwise to remove it from insulator panel. Slide insulator panel to rear and remove from vehicle. Remove center console. See «CENTER CONSOLE»(ref-91547-S23464809052001042500000) .
3. Remove lower dashboard support bracket. Remove auxiliary air distribution duct adapter. Remove air distribution duct screws and remove duct. Remove heater core heat shield screws and remove heat shield. Remove 7 heater core cover screws and heater core cover. Remove heater core retaining screws and strap from heater core. Remove heater core.
4. To install, reverse removal procedure. Leave out right air distribution duct screw, due to difficulty reinstalling it. Charge A/C system.

1. Pull instrument panel radio trim plate to rear and disengage clips and remove trim plate. Pinch tabs in and remove control head from instrument panel.
2. To install, reverse removal procedure. HVAC control head must be reprogrammed. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove evaporator nut and hose connection at evaporator. Remove both heater hoses from heater core. Remove instrument panel. See «INSTRUMENT PANEL»(ref-91547-S13405535292001032600000) .
2. Remove lower instrument panel support bracket. Remove 2 defroster duct retaining screws and one nut. Remove defroster duct. Remove air distributor duct retaining screws and remove duct. Disconnect blower control module harness connector. Remove instrument panel to HVAC assembly harness connector. Remove 4 HVAC assembly retaining nuts. Remove HVAC assembly. To install, reverse removal procedure. Charge A/C system.

Pull instrument panel to rear and disengage clips and remove trim plate. Remove knee bolster, by pulling past holding tab and lifting up. Unsnap knee bolster by pulling down and to rear and remove from vehicle. Pull inside air temperature sensor out from under instrument panel and from aspirator hose. To install, reverse removal procedure.

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Disconnect negative battery cable. Remove 2 screws securing lower dashboard insulator panel to instrument panel retainer. Remove air temperature sensor from closeout insulator panel by turning 1/4 turn counterclockwise. Disconnect harness connector from lower instrument panel courtesy light. Slide lower dashboard insulator panel to rear in order to remove it from vehicle. Remove fasteners and push in retainers, holding lower dashboard insulator panel to dashboard. Turn air temperature sensor 1/4 turn counterclockwise to remove from insulator panel. Slide insulator panel to rear and remove from vehicle. Gently pry out on both right and left instrument outer trim covers.
2. Pull windshield garnish molding away from windshield pillar at bottom of molding to disengage 2 clips. Slide molding out past tabs at top of molding. Carefully pry defroster grille upward to release retainers. Disconnect harness connector from sun load sensor and remove sun load sensor. Open glove box and remove 2 screws that hold instrument panel radio trim plate in place and pull toward rear of vehicle. Remove glove box light switch wiring harness and remove instrument panel radio trim plate. Lower steering column to lowest position. Pry out on ignition lock bezel and remove. Pull radio panel trim plate to rear and disengage clips and remove trim plate. (Scheme 5) Remove 2 screws from instrument cluster upper trim plate. Push from rear of left air vent and pull put. Disconnect dimmer switch harness connector. Remove 3 screws from inside instrument panel trim pad defrost grille area. Remove 2 screws on right side and 2 screws on left side of instrument panel trim pad. Pull up on trim pad and remove.
3. Remove center console. See «CENTER CONSOLE»(ref-91547-S23464809052001042500000). Depress spring clips on each side of radio and pull straight out and remove radio. Depress spring clips on each side of HVAC control head and pull straight out and remove HVAC control head. Depress spring clips on each side of driver information center module and pull straight out and remove driver information center module. Remove knee bolster, by pulling past holding tab and lifting up. Unsnap knee bolster by pulling down and to rear and remove from vehicle. Remove retainers securing knee bolster bracket to instrument panel and steering column support. Remove knee bolster bracket.
4. Remove 4 nuts securing steering column to instrument panel and let column drop down. Release 4 instrument cluster pins and pull out and remove instrument cluster. Pry down at top of valet switch. Remove wiring harness and remove valet switch. Remove 4 screws that hold glove box door to instrument panel. Pull toward rear on glove box door and remove door. Remove fasteners that secure glove box door to glove box. Disconnect right, center and left instrument panel to body wiring harness connectors. Remove 8 bolts securing instrument panel retainer to instrument panel carrier. Remove instrument panel retainer from carrier, feed wiring through openings as necessary.
5. Remove data link connector fasteners. Remove passenger air bag module. See appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES & EQUIPMENT. Disconnect ignition switch harness connector. Remove shift/park cable from ignition switch. Disconnect body to instrument panel harness connector located at upper right outside corner of instrument panel carrier. Remove aspirator tube. Feed ignition switch wiring, shift/park lock cable and center console wiring harnesses through instrument panel carrier. Remove air bag system harness retainer from instrument panel carrier. Remove 2 nuts and 11 screws from instrument panel carrier and remove carrier from vehicle. (Scheme 7) To install, reverse removal procedure.

Scheme 7

Remove 2 screws securing lower dashboard insulator panel to instrument panel retainer. Remove air temperature sensor from closeout insulator panel by turning 1/4 turn counter clockwise. Disconnect harness connector from lower instrument panel courtesy light. Slide lower dashboard insulator panel to rear in order to remove it from vehicle. Remove screw, holding instrument panel module to under side of instrument panel carrier. Rotate IPM up and out of instrument panel retainer. Disconnect harness connector. To install, reverse removal procedure. IPM must be reprogrammed. See BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.

Remove left air temperature door actuator. See AIR TEMPERATURE DOOR ACTUATORS . Remove mode actuator retaining screws and remove mode actuator. To install, reverse removal procedure.

Remove HVAC head. See HVAC CONTROL HEAD . Remove mode actuator. See MODE ACTUATOR . Remove recirculation actuator. Remove left air temperature mode actuator. See AIR TEMPERATURE DOOR ACTUATORS . Remove mode actuator bracket fasteners and bracket. Remove upper module case fasteners. Peel back foam from heater inlet and remove upper case. Remove actuator cam from door and remove mode door. To install reverse removal procedure.

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect harness connector from orifice solenoid. Disconnect orifice solenoid from actuator cover. Disconnect hose fittings at each end of orifice solenoid. Remove orifice solenoid. Remove filter screen from orifice solenoid. To install, reverse removal procedure. Lubricate "O" ring with refrigerant oil.

Lift access cover on air inlet panel. Remove filter from housing. Replace filter and close housing.

Remove right temperature switch plate by prying up on forward edge, using a tool with a flat blade. Disconnect harness connector. Remove passenger-side temperature control switch assembly from switch plate. To install, reverse removal procedure.

1. Remove fasteners and push in retainers, holding lower dashboard insulator panel to dashboard. Turn air temperature sensor 1/4 turn counterclockwise to remove it from insulator panel. Disconnect harness connector from lower instrument panel courtesy light. Slide insulator panel to rear and remove from vehicle.
2. Remove 4 screws that hold glove box door to instrument panel. Pull toward rear on glove compartment door and remove door. Remove fasteners that secure glove box door to glove box. Remove Dashboard Integration Module (DIM) from bracket and position to side.
3. Remove rear DIM bracket screws and lower bracket far enough to gain access to recirculation actuator. Remove harness connector from recirculation actuator. Remove recirculation actuator retaining screws and remove actuator.
4. To install, reverse removal procedure. Recalibrate actuators. See «RE-CALIBRATING ACTUATORS»(ref-91547-S03313830272001041200000) under PROGRAMMING.

Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove steering wheel air bag module. Gently pry steering wheel control switch away from steering wheel. Disconnect steering wheel control switch harness connector and remove switch. To install, reverse removal procedure.

Carefully pry defrost grille upward to release retainers. Disconnect harness connector from sun load sensor and remove sun load sensor. To install, reverse removal procedure.