Heating, Ventilation, and Air Conditioning: Removal & Installation — Heating, Ventilation, and Air Conditioning — Automatic HVAC System

Compressor Replacement (LNF)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . Remove the drive belt. Refer to Drive Belt Replacement .
1	A/C Compressor and Condenser Hose Assembly Bolt NOTE: Refer to Fastener Notice . Tighten: 22 N.m (16 lb ft)
2	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3	A/C Compressor Bolt (Qty: 3) Tip: Tighten bolts in sequence. Tighten: 22 N.m (16 lb ft)
4	A/C Compressor Assembly

NOTE
Refer to Fastener Notice .

Compressor Replacement (2.0L)

Removal Procedure

Remove the seal washer from the A/C refrigerant component.
Inspect the seal washer for signs of damage to help determine the root cause of the failure.
Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
Discard the sealing washer.

Installation Procedure

Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
Remove the cap or tape from the A/C refrigerant components.
Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting.
Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.

Scheme 2

Scheme 2: Compressor Hose Assembly Replacement (LE5)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1	A/C Compressor and Condenser Hose Assembly Nut NOTE: Refer to Fastener Notice . Tip: A/C compressor hose to A/C evaporator hose Tighten: 9 N.m (80 lb in)
2	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3	A/C Compressor and Condenser Hose Assembly Nut Tip: A/C compressor hose to A/C condenser. Tighten: 9 N.m (80 lb in)
4	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
5	A/C Compressor and Condenser Hose Assembly Bolt Tighten: 22 N.m (16 lb ft)
6	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
7	A/C Compressor and Condenser Hose Assembly

NOTE
Refer to Fastener Notice .

Compressor Hose Assembly Replacement (2.4L)

Compressor Hose Assembly Replacement (LNF)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1	A/C Compressor and Condenser Hose Assembly Nut NOTE: Refer to Fastener Notice . Tip: A/C compressor hose to A/C evaporator hose Tighten: 9 N.m (80 lb in)
2	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3	A/C Compressor and Condenser Hose Assembly Nut Tip: A/C compressor hose to A/C condenser Tighten: 9 N.m (80 lb in)
4	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
5	A/C Compressor and Condenser Hose Assembly Bolt Tighten: 22 N.m (16 lb ft)
6	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
7	A/C Compressor and Condenser Hose Assembly

NOTE
Refer to Fastener Notice .

Compressor Hose Assembly Replacement (2.0L)

Scheme 3

Scheme 3: Condenser Tube Replacement (LE5)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1	A/C Condenser Tube Assembly Nut NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3	Push Pin Retainer
4	A/C Condenser Tube Assembly Nut Tighten: 9 N.m (80 lb in)
5	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
6	A/C Condenser Tube Assembly

NOTE
Refer to Fastener Notice .

Condenser Tube Replacement (2.4L)

Scheme 4

Scheme 4: Condenser Tube Replacement (LNF)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1	A/C Condenser Tube Assembly Nut NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3	Push Pin Retainer
4	A/C Condenser Tube Assembly Nut Tighten: 9 N.m (80 lb in)
5	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
6	A/C Condenser Tube Assembly

NOTE
Refer to Fastener Notice .

Condenser Tube Replacement (2.0L)

Scheme 5

Scheme 5: Evaporator Tube Replacement (LE5)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement .
1	A/C Condenser Tube Assembly Nut NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2	Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
3	A/C Compressor and Condenser Hose Assembly Nut Tighten: 9 N.m (80 lb in)
4	Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
5	A/C Evaporator Hose Assembly Clip Nut (Qty: 2) Tighten: 9 N.m (80 lb in)
6	A/C Evaporator Hose Assembly Bolt (Qty: 2) Tighten: 16 N.m (12 lb ft)
7	Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
8	A/C Evaporator Hose Assembly

NOTE
Refer to Fastener Notice .

Evaporator Tube Replacement (2.4L)

Scheme 6

Scheme 6: Evaporator Tube Replacement (LNF)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement .
1	A/C Condenser Tube Assembly Nut NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2	Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
3	A/C Compressor and Condenser Hose Assembly Nut Tighten: 9 N.m (80 lb in)
4	Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
5	A/C Evaporator Hose Assembly Clip Nut (Qty: 2) Tighten: 9 N.m (80 lb in)
6	A/C Evaporator Hose Assembly Bolt (Qty: 2) Tighten: 16 N.m (12 lb ft)
7	Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
8	A/C Evaporator Hose Assembly

NOTE
Refer to Fastener Notice .

Evaporator Tube Replacement (2.0L)

Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(ref-267906-S00952295222007101700000) .
Remove the A/C refrigerant valve (2).
Remove and discard the O-ring seal (3).

Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil.
Install the O-ring seal (3) onto the valve if necessary.
Install the A/C refrigerant valve (2). Tighten: Tighten the valve to 11 N.m (98 lb in).
Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-267906-S00952295222007101700000) .
Leak test the fitting valve area using the J 39400-A .
Install the service port cap (1).

Scheme 7

Scheme 7: Receiver Dehydrator Replacement (LE5)

Callout	Component Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
1	Receiver Dehydrator Screw Tighten: 1.5 N.m (13 lb in)
2	Receiver Dehydrator Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
3	Receiver Dehydrator O-Ring Tip: Remove and discard the O-rings.
4	Receiver and Dehydrator Assembly, A/C

NOTE
Refer to Fastener Notice .

Receiver Dehydrator Replacement (2.4L)

Scheme 8

Scheme 8: Receiver Dehydrator Replacement (LNF)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the charge air cooler. Refer to Charge Air Cooler Replacement . Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
1	Receiver Dehydrator Screw NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2	Receiver Dehydrator Screw Tighten: 1.5 N.m (13 lb in)
3	Receiver Dehydrator O-Ring Tip: Remove and discard the O-rings.
4	Receiver and Dehydrator Assembly, A/C

NOTE
Refer to Fastener Notice .

Receiver Dehydrator Replacement (2.0L)

Scheme 9

Scheme 9: Thermal Expansion Valve Replacement

Callout	Component Name
Preliminary Procedure: Recover the A/C system. Refer to Refrigerant Recovery and Recharging .
1	A/C Compressor Tube Assembly Nut NOTE: Refer to Fastener Notice . Tighten: 16 N.m (12 lb ft)
2	Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
3	Thermal Expansion Valve Bolts (Qty: 2) Tighten: 16 N.m (12 lb ft)
4	Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
5	Thermal Expansion Valve

NOTE
Refer to Fastener Notice .

Thermal Expansion Valve Replacement

Scheme 10

Scheme 10: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement

Callout	Component Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Disconnect the electrical connector from the A/C pressure sensor.
1	Sensor, A/C Refrigerant Pressure Tighten: 5 N.m (44 lb in)
2	O-Ring, Seal Tip: Remove and discard O-ring.

NOTE
Refer to Fastener Notice .

A/C Refrigerant Pressure Sensor Replacement

Scheme 11

Scheme 11: Evaporator Temperature Sensor Replacement

Callout	Component Name
Preliminary Procedure: Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
1	Heater Core Cover Screw NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2	Heater Core Cover
3	Air Conditioning Refrigerant Temperature Sensor Tip: Disconnect the air conditioning refrigerant temperature sensor electrical connector. Twist the air conditioning refrigerant temperature sensor to the left to release and pull upward.

NOTE
Refer to Fastener Notice .

Evaporator Temperature Sensor Replacement

Scheme 12

Scheme 12: Condenser Replacement (LE5)

Callout	Component Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
1	A/C Condenser Tube Nut Tighten: 9 N.m (80 lb in)
2	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3	A/C Compressor and Condenser Hose Nut Tighten: 9 N.m (80 lb in)
4	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
5	A/C Condenser Bolt Tighten: 9 N.m (80 lb in)
6	Radiator Assembly Bolt Tighten: 25 N.m (18 lb ft)
7	Receiver Dehydrator Assembly Bolt Tighten: 6 N.m (53 lb in)
8	Receiver Dehydrator Assembly Bolt Tighten: 6 N.m (53 lb in)
9	O-Ring Tip: Remove and discard O-rings.
10	A/C Receiver Dehydrator Assembly
11	A/C Condenser Assembly

NOTE
Refer to Fastener Notice .

Condenser Replacement (2.4L)

Scheme 13

Scheme 13: Condenser Replacement (LNF)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement . Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement . Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
1	A/C Condenser Tube Nut NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3	A/C Compressor and Condenser Hose Nut Tighten: 9 N.m (80 lb in)
4	Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
5	A/C Condenser Bolt Tighten: 9 N.m (80 lb in)
6	Radiator Assembly Bolt Tighten: 25 N.m (18 lb ft)
7	Receiver Dehydrator Assembly Bolt Tighten: 6 N.m (53 lb in)
8	Receiver Dehydrator Assembly Bolt Tighten: 6 N.m (53 lb in)
9	O-Ring Tip: Remove and discard O-rings.
10	A/C Receiver Dehydrator Assembly
11	A/C Condenser Assembly

NOTE
Refer to Fastener Notice .

Condenser Replacement (2.0L)

Scheme 14

Scheme 14: Air Conditioning (A/C) Evaporator Case Assembly Replacement

Callout	Component Name
Preliminary Procedure Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement . Remove the heater core cover. Refer to Heater Core Cover Replacement . Remove the air inlet assembly. Refer to Air Inlet Assembly Replacement . Note routing of electrical wiring to ensure proper installation. Disconnect the 5 electrical connectors.
1	Rear Air Outlet Duct Screw (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2	Rear Air Outlet Duct
3	Drain Tube, Evaporator Case Seal
4	Evaporator Case Assembly Screw (Qty: 10) Tighten: 1.5 N.m (13 lb in)
5	Air Distributor
6	Evaporator Case - Lower
7	Evaporator Case - Upper
8	Air Conditioning Evaporator
9	Blower Motor Resistor Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
10	Blower Motor Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
11	Blower Motor Assembly
12	Air Inlet Housing Baffle

NOTE
Refer to Fastener Notice .

A/C Evaporator Case Assembly Replacement

Scheme 15

Scheme 15: HVAC Module Assembly Replacement

Callout	Component Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the evaporator tube from the thermal expansion valve. Refer to Thermal Expansion Valve Replacement . Remove the heater inlet hose from the heater core. Refer to Heater Inlet Hose Replacement (LE5) or Heater Inlet Hose Replacement (LNF) . Remove the heater outlet hose from the heater core. Refer to Heater Outlet Hose Replacement (LE5) or Heater Outlet Hose Replacement (LNF) . Remove the instrument panel (I/P) tie bar. Refer to Instrument Panel Tie Bar Replacement . Disconnect the HVAC module assembly electrical connectors.
1	Nut, HVAC Module Assembly (Qty: 5) Tighten: 9 N.m (80 lb in)
2	Module, HVAC Assembly Tip: Note routing of wiring harness to ensure proper installation.

NOTE
Refer to Fastener Notice .

HVAC Module Assembly Replacement

Scheme 16

Scheme 16: Evaporator Core Replacement

Callout	Component Name
Preliminary Procedure: Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
1	Evaporator Case Seal
2	Thermal Expansion Valve Bolts (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
3	Thermal Expansion Valve
4	Sealing Washer Tip: Remove and discard seals. Refer to Sealing Washer Replacement .
5	Rear Air Outlet Duct Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
6	Rear Air Outlet Duct
7	Lower Evaporator Case Assembly Screw (Qty: 9) Tighten: 1.5 N.m (13 lb in)
8	Evaporator Case - Lower
9	Air Conditioning Evaporator

NOTE
Refer to Fastener Notice .

Evaporator Core Replacement

Scheme 17

Scheme 17: Heater Inlet Hose Replacement (LE5)

Callout	Component Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
1	Heater Inlet Hose Assembly Using the SA9111E reposition the heater inlet hose clamp.

Heater Inlet Hose Replacement (2.4L)

Scheme 18

Scheme 18: Heater Inlet Hose Replacement (LNF)

Callout	Component Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
1	Heater Inlet Hose Assembly Using SA9111E reposition the heater inlet hose clamp.

Heater Inlet Hose Replacement (2.0L)

Scheme 19

Scheme 19: Heater Outlet Hose Replacement (LE5)

Callout	Component Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
1	Heater Outlet Hose Assembly Using SA9111E reposition the heater outlet hose clamp.

Heater Outlet Hose Replacement (2.4L)

Scheme 20

Scheme 20: Heater Outlet Hose Replacement (LNF)

Callout	Component Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
1	Heater Outlet Hose Assembly Using SA9111E reposition the heater outlet hose clamp.

Heater Outlet Hose Replacement (2.0L)

Scheme 21

Scheme 21: Air Inlet Assembly Replacement

Callout	Component Name
Preliminary Procedure: Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
1	Air Inlet Housing Screw (Qty: 6) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2	Recirculation Actuator Screw (Qty: 3) Tighten: 1.5 N.m (13 lb in)
3	Recirculation Actuator
4	Air Inlet Housing

NOTE
Refer to Fastener Notice .

Air Inlet Assembly Replacement

Scheme 22

Scheme 22: Air Inlet Housing Front Panel Replacement

Callout	Component Name
Preliminary Procedures Remove the 3 hold down bolts for the underhood electrical center and position aside. Refer to Underhood Electrical Center or Junction Block Replacement . Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
1	Air Inlet Housing Nuts (Qty: 5) NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2	Air Inlet Housing Front Panel Assembly

NOTE
Refer to Fastener Notice .

Air Inlet Housing Front Panel Replacement

Scheme 23

Scheme 23: Blower Motor Resistor Replacement

Callout	Component Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Remove the I/P compartment. Refer to Instrument Panel Compartment Replacement . Disconnect the blower motor resistor electrical connector.
1	Screw, Blower Motor Resistor (Qty 2) Tighten: 1.5 N.m (13 lb in)
2	Resistor, Blower Motor

NOTE
Refer to Fastener Notice .

Blower Motor Resistor Replacement

Scheme 24

Scheme 24: Blower Motor Replacement

Callout	Component Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Remove the instrument panel (I/P) compartment. Refer to Instrument Panel Compartment Replacement . Disconnect the blower motor resistor electrical connector.
1	Screw, Blower Motor Resistor (Qty: 2) Tighten: 1.5 N.m (13 lb in)
2	Resistor, Blower Motor
3	Screw, Blower Motor (Qty: 3) Tighten: 1.5 N.m (13 lb in)
4	Motor Assembly, Blower

NOTE
Refer to Fastener Notice .

Blower Motor Replacement

Scheme 25

Scheme 25: Instrument Panel Outer Air Outlet Deflector Replacement - Left Side

Callout	Component Name
Preliminary Procedure: Remove the instrument panel (I/P) trim pad. Refer to Instrument Panel Trim Pad Replacement .
1	Instrument Panel Outer Air Outlet Grille Assembly - Left

Instrument Panel Outer Air Outlet Deflector Replacement - Left Side

Scheme 26

Scheme 26: Instrument Panel Outer Air Outlet Deflector Replacement - Center

Callout	Component Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Remove the instrument panel (I/P) cluster trim plate. Refer to Instrument Cluster Trim Panel Replacement .
1	Outlet, Air Center Grille Tip: Remove the foam from the rear of the center air outlet. Depress the tabs and pull the air outlet grille from the center instrument panel cluster trim plate.

Instrument Panel Outer Air Outlet Deflector Replacement

Scheme 27

Scheme 27: Instrument Panel Outer Air Outlet Deflector Replacement - Right Side

Callout	Component Name
Preliminary Procedure: Remove the Instrument Panel Trim Pad. Refer to Instrument Panel Trim Pad Replacement .
1	Grille Assembly, Instrument Panel (I/P) Outer Air Outlet - Right

Instrument Panel Outer Air Outlet Deflector Replacement - Right Side

Scheme 28

Scheme 28: Air Distributor Duct Replacement

Callout	Component Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Remove the Instrument Panel (I/P) carrier. Refer to Instrument Panel Carrier Replacement . IMPORTANT: Pull the tie bar far enough back for the air distribution duct to clear the opening. Remove the I/P tie bar. Refer to Instrument Panel Tie Bar Replacement .
1	Nut, Distributor Air Tighten: 2.5 N.m (16 lb in)
2	Bolt, Distributor Air Tighten: 2.5 N.m (16 lb in)
3	Distributor, Air

NOTE
Refer to Fastener Notice .

IMPORTANT
Pull the tie bar far enough back for the air distribution duct to clear the opening.

Air Distributor Duct Replacement

Scheme 29

Scheme 29: Heater Core Cover Replacement

Callout	Component Name
Preliminary Procedure: Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
1	Heater Core Cover Screw (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2	Heater Core Cover

NOTE
Refer to Fastener Notice .

Heater Core Cover Replacement

Scheme 30

Scheme 30: Heater Core Replacement

Callout	Component Name
Preliminary Procedure Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement . Disconnect the actuator electrical connectors from the air distribution case.
1	Screw, Air Outlet Duct NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (14 lb in)
2	Duct, Air Outlet
3	Screw, Heater Core Cover Tighten: 1.5 N.m (14 lb in)
4	Cover, Heater Core
5	Seal, Heater Core Pass Through
6	Screw, Air Distribution Case Tighten: 1.5 N.m (14 lb in)
7	Case, Air Distribution
8	Screw, Heater Core Bracket (Qty: 2) Tighten: 1.5 N.m (14 lb in)
9	Bracket, Heater Core
10	Core, Heater

NOTE
Refer to Fastener Notice .

Heater Core Replacement

Heating, Ventilation, and Air Conditioning: Removal & Installation Pontiac Solstice I