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Climate System: Component Locations Saab 9-4X I

Automatic HVAC System 100 illustrations ~4243 words

Special Tools

Illustration Tool Number/Description BO 38185 J 38185 Hose Clamp Pliers GE 41447 J 41447 R-134a A/C Tracer Dye - Box of 24 GE 42220 J 42220 Universal 12V Leak Detection Lamp GE-48800 Cool Tech A/C Recharge Machine GE 8800 J 43600 ACR 2000 Air Conditioning Service Center GE 43872 J 43872 Fluorescent Dye Cleaner GE 44551 J 44551 Suction Screen Installation/Removal Kit GE 45037 J 45037 A/C Oil Injector GE 45268 J 45268 A/C Flushing Adapter Kit GE 50078 Electronic Leak Detector J 46246 Charge Port Valve Core Remover/Installer J 46297 A/C Dye Injector Kit GE 46297-12 J 46297-12 Replacement Dye Cartridges 7000086I Scan Tool Used for diagnosis of vehicle electrical system

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Scheme 1: Special Tools
Scheme 1: Special Tools

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Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10
  1. GE-50078 Infrared Refrigerant Leak Detector
  2. GE-41447 R-134A A/C Tracer Dye, Box of 24
  3. GE-42220 Universal 12V Leak Detection Lamp
  4. GE-43872 Fluorescent Dye Cleaner
  5. GE-46297 A/C Dye Injector Kit
  6. GE-46297-12 Replacement Dye Cartridges

For equivalent regional tools. Refer to SPECIAL TOOLS

Location (pos)

  1. 01 - Front
  2. 02 - Rear
  3. 03 - Left
  4. 04 - Right Hand
  5. 05 - All
  6. 06 - Upper
  7. 07 - Center
  8. 08 - Lower
  9. 09 - Service Information
  1. GE-48800 CoolTech A/C Recharge Machine
  2. J-43600 ACR 2000 Air Conditioning Service Center
  3. J-45037 A/C Oil Injector

For equivalent regional tools, refer to SPECIAL TOOLS

WARNINGTo prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. When removing refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing with the service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers.
WARNINGFor personal protection, goggles and lint-free gloves should be worn and a clean lint free cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained.
WARNINGYou must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the desiccant will result in damage to the A/C refrigerant system.
WARNINGR-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure and potentially void the vehicle warranty for the refrigerant system.
WARNINGTo avoid system damage use only R-134a dedicated tools when servicing the A/C system.
WARNINGDo not lubricate A/C line seal washers as mineral oil will damage the seal and cause leaks. Use only 525 viscosity mineral oil to lubricate o-rings as well as fitting threads for the prevention of fitting seizure.
WARNINGUse only GM approved Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system.

Both the J-43600 ACR 2000 Air Conditioning Service Center and GE-48800 CoolTech A/C Recharge Machine are complete air conditioning service center for R-134a. Both units recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. Both units have a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. Both units automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant.

The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system.

The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.

The GE-48800 CoolTech A/C filling machine has been introduced as a necessary replacement for the previous important J-43600 ACR 2000 Air conditioning, service center. The GE-48800 CoolTech A/C filling machine complies with SAE J2788 and meets GM's requirements for the repair of A/C refrigerants on all GM vehicles, including hybrid systems with polyolester (POE) refrigerant oil.

Refer to the J-43600 ACR 2000 Air Conditioning Service Center or GE-48800 CoolTech A/C Recharge Machine manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to REFRIGERANT SYSTEM SPECIFICATIONS for the correct amount.

  1. GE-8800 ACR 2000 Air Conditioning Service Center
  2. GE-45268 Flush Adapter Kit
  3. GE-41447 Leak Detection Dye
  4. GE-42220 Universal 12V Leak Detection Lamp

For equivalent regional tools. Refer to SPECIAL TOOLS

Note. Flushing with the GE-8800 ACR 2000 Air Conditioning Service Center is not intended to remove metal from the A/C system.

Flushing is intended to remove the following

  1. Contaminated polyalkylene glycol (PAG) oil
  2. Desiccant, following a desiccant bag failure
  3. Overcharge of PAG oil
  4. Refrigerant contamination

Scheme 11

Scheme 11
Scheme 11
  1. NOTE: Warmer engine or ambient temperature decreases the refrigerant recovery time during the A/C flush procedure. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR)»(ref-652243-S08177155752014082300000)
  2. Remove the thermal expansion valve (TXV). Refer to «AIR CONDITIONING EVAPORATOR THERMAL EXPANSION VALVE REPLACEMENT»(ref-652243-S07910674552014082300000)
  3. Install the stud for the GE 45268 Flush Adapter kit onto the GE 45268-121.
  4. Install the GE 45268-121 in place of the TXV.
  5. Refer to «FASTENER CAUTION»(ref-652229-S20487768742014082300000) . Install the TXV mounting bolts. Tighten Tighten the bolts to 7 Nm (62 lb in).
  6. Connect the evaporator line to the GE 45268-121.
  7. Install the TXV block fitting nut. Tighten Tighten the bolts to 17 Nm (12.5 lb ft).
  8. Remove the A/C compressor. Refer to «A/C COMPRESSOR, REPLACEMENT (LF1)»(ref-652243-S18596798422014082300000) or «A/C COMPRESSOR, REPLACEMENT (LAU)»(ref-652243-S14698244962014082300000)
  9. Install GE 45268-10 to the A/C compressor hose assembly.
  10. Install the nut and bolt from the GE 45268 Flush Adapter kit to the GE 45268-10 and compressor hose assembly. Tighten Tighten the bolts to 17 Nm (12.5 lb ft).
  11. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil. Perform the following procedure: 11.1. NOTE: The filter inside GE 45268-1 is serviceable. Remove and discard the check valve from the filter. Service the filter with ACDelco P/N GF 470, before each flush. 11.2. Install the port plugs GE 45268-9 onto the GE 45268-10. 11.3. Install the fitting GE 45268-7 onto the GE 45268-10. 11.4. Install the fitting GE 45268-8 onto the GE 45268-10. 11.5. Connect GE 45268-1 flush filter to the suction port of GE 45268-7 flush adapter. 11.6. Connect the blue hose from the GE 8800 ACR 2000 Air Conditioning Service Center to the GE 45268-1 flush filter adapter. 11.7. Connect the red hose from the GE 8800 ACR 2000 Air Conditioning Service Center to the GE 45268-8 flush adapter.
  12. Reverse flow refrigerant flush is recommended for desiccant bag failure. Replace the A/C condenser when the A/C flush is complete and perform the following procedure: 12.1. NOTE: The filter inside GE 45268-1 is serviceable. Remove and discard the check valve from the filter. Service the filter with ACDelco P/N GF 470, before each flush. 12.2. Install the port plugs GE 45268-9 onto the J 45268-10. 12.3. Install the fitting GE 45268-7 onto the J 45268-10. 12.4. Install the fitting GE 45268-8 onto the J 45268-10. 12.5. Connect GE 45268-1 flush filter to the discharge port of GE 45268-7 flush adapter. 12.6. Connect the blue hose from the GE 8800 ACR 2000 Air Conditioning Service Center to the GE 45268-1 flush filter adapter. 12.7. Connect the red hose from the GE 8800 ACR 2000 Air Conditioning Service Center to the GE 45268-8 flush adapter.
  13. NOTE: Close the valve on the external refrigerant tank, before starting the flush process. Flush the A/C system. Follow the instructions for the GE 8800 ACR 2000 A/C service center.
  14. Disconnect the red hose on the GE 8800 ACR 2000 Air Conditioning Service Center from the GE 45268-10.
  15. Disconnect the blue hose on the GE 8800 ACR 2000 Air Conditioning Service Center from the GE 45268-1.
  16. Remove GE 45268-1 from the GE 45268-10.
  17. Remove the GE 45268-10 from the A/C compressor hose assembly.
  18. NOTE: The A/C system must be replenished with the correct amount of PAG oil. Flushing will remove all the PAG oil from the A/C system. If you will reinstall the removed A/C compressor, perform the following procedure: 18.1. Remove the A/C compressor drain plug. 18.2. Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor. 18.3. Install the A/C compressor drain plug. Tighten Tighten the drain plug to 16 Nm (12 lb ft). 18.4. Add the total system capacity of PAG oil to the A/C compressor. Refer to «REFRIGERANT SYSTEM SPECIFICATIONS»(ref-652243-S35763723512014082300000)
  19. If you will replace the A/C compressor after flushing the system, perform the following procedure: 19.1. Determine if the new service compressor is shipped with PAG oil. Refer to «REFRIGERANT SYSTEM SPECIFICATIONS»(ref-652243-S35763723512014082300000) 19.2. If the service compressor is shipped with PAG oil, DO NOT drain the new PAG oil from the compressor. 19.3. Deduct the amount of PAG oil shipped with the service compressor from the amount of PAG oil listed in the capacities table. Refer to «REFRIGERANT SYSTEM SPECIFICATIONS»(ref-652243-S35763723512014082300000) 19.4. Add the calculated amount to the compressor, as needed.
  20. NOTE: Flushing will remove the fluorescent leak detection dye from the A/C system. Add one bottle of GE 41447 Leak Detection Dye directly to the A/C Compressor.
  21. Fit the A/C compressor. Refer to «A/C COMPRESSOR, REPLACEMENT (LF1)»(ref-652243-S18596798422014082300000) or A/C «COMPRESSOR, REPLACEMENT (LAU)»(ref-652243-S14698244962014082300000)
  22. Remove GE 45268-121.
  23. Inspect the TXV for debris. Clean or replace as needed.
  24. Install the TXV. Refer to «AIR CONDITIONING EVAPORATOR THERMAL EXPANSION VALVE REPLACEMENT»(ref-652243-S07910674552014082300000)
  25. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR)»(ref-652243-S08177155752014082300000)
  26. Leak test the fittings using GE 42220 Universal 12V Leak Detection Lamp

Scheme 12

Scheme 12: Draining Procedure
Scheme 12: Draining Procedure
  1. NOTE: Drain and measure as much of the refrigerant oil as possible from the rear head ports of the REMOVED compressor. Drain the refrigerant oil from the crankcase and rear head ports into a clean, graduated container.
  2. Rotate the compressor shaft to assist in draining the compressor.
  3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
  4. Inspect oil drained from removed compressor. Refer to «AIR CONDITIONING COMPRESSOR OIL DIAGNOSIS»(ref-652243-S38165302102014082300000) .
  5. Properly discard the used refrigerant oil.
  6. Clean the graduated cylinder.
  7. NOTE: Drain and measure as much of the refrigerant oil as possible from the rear head ports of the NEW compressor. Drain bolt and drain the refrigerant oil from the crankcase and rear head ports into a clean, graduated container.
  8. Rotate the compressor shaft to assist in draining the compressor.

Scheme 13

Scheme 13: Balancing Procedure
Scheme 13: Balancing Procedure
  1. NOTE: The refrigerant oil in the A/C system must be balanced during compressor replacement. The replacement compressor is shipped with the total system capacity of refrigerant oil. Refer to the amount of refrigerant oil recorded during the compressor removal.
  2. If the amount of oil recorded from the removed compressor is less than or equal to 75 ml (2.5 fl. oz.), add 75 ml of the new PAG oil back into the new compressor through the compressor suction port.
  3. If the amount of oil recorded from the removed compressor is greater than 75 ml (2.5 fl. oz.), add the equivalent amount of the new PAG oil back into the new compressor through the compressor suction port.
  4. Rotate the clutch driver three times to lubricate the internal compressor components.
  5. NOTE: If additional A/C components are replaced during compressor replacement, add the PAG oil directly to the A/C compressor to compensate the A/C system. If necessary, refer to «REFRIGERANT SYSTEM SPECIFICATIONS»(ref-652243-S35763723512014082300000) .

Scheme 14

Scheme 14: Air Conditioning Compressor Replacement (LF1)
Scheme 14: Air Conditioning Compressor Replacement (LF1)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR) . Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE Remove front wheelhouse liner. Refer to FRONT WHEELHOUSE LINER REPLACEMENT . Remove the drive belt from the compressor. Refer to DRIVE BELT REPLACEMENT . Disconnect the A/C compressor electrical connector. Remove the air conditioning condenser and evaporator hose from the compressor. Refer to HOSE REPLACEMENT (LF1) or HOSE REPLACEMENT (LAU) .
1A/C Compressor Bolt Refer to FASTENER CAUTION . Tighten 58 Nm (43 lb ft)
2A/C Compressor Nut Tighten 22 Nm (12 lb ft)
3A/C Compressor Bolt Tighten 58 Nm (43 lb ft)
4A/C Compressor Procedure Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT . When replacing the A/C compressor, balance the compressor oil. Refer to AIR CONDITIONING COMPRESSOR OIL BALANCING .

Scheme 15

Scheme 15: Air Conditioning Compressor Replacement (LAU)
Scheme 15: Air Conditioning Compressor Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR) . Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE Remove front wheelhouse liner. Refer to FRONT WHEELHOUSE LINER REPLACEMENT . Remove the drive belt. Refer to DRIVE BELT REPLACEMENT . Disconnect the A/C compressor electrical connector. Remove the air conditioning condenser and evaporator hose. Refer to HOSE REPLACEMENT (LF1) or HOSE REPLACEMENT (LAU) .
1A/C Compressor Bolt Refer to FASTENER CAUTION . Tighten 22 Nm (22 lb ft)
2A/C Compressor Procedure Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT . When replacing the A/C compressor, balance the compressor oil. Refer to AIR CONDITIONING COMPRESSOR OIL BALANCING .

Scheme 16

Scheme 16: Compressor Pressure Relief Valve Replacement (LF1)
Scheme 16: Compressor Pressure Relief Valve Replacement (LF1)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR) . Remove the air conditioning compressor. Refer to COMPRESSOR REPLACEMENT (LF1) or COMPRESSOR REPLACEMENT (LAU) .
1Compressor Pressure Relief Valve Refer to FASTENER CAUTION . Procedure Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT . Tighten 8 Nm (70 lb in)

Scheme 17

Scheme 17: Compressor Pressure Relief Valve Replacement (LAU)
Scheme 17: Compressor Pressure Relief Valve Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR) . Remove the air conditioning compressor. Refer to COMPRESSOR REPLACEMENT (LF1) or COMPRESSOR REPLACEMENT (LAU) .
1Compressor Pressure Relief Valve Refer to FASTENER CAUTION . Procedure Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT . Tighten 8 Nm (70 lb in)

Scheme 18

Scheme 18: Air Conditioning Compressor Bracket Replacement (LAU)
Scheme 18: Air Conditioning Compressor Bracket Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Remove the compressor. Refer to COMPRESSOR REPLACEMENT (LF1) or COMPRESSOR REPLACEMENT (LAU) .
1A/C Compressor Bracket Bolts (Qty 3). Refer to FASTENER CAUTION . Tighten 58 Nm (43 lb ft)
2A/C Compressor Bracket

Scheme 19

Scheme 19: Removal Procedure
Scheme 19: Removal Procedure
  1. Remove the seal washer from the A/C refrigerant component.
  2. Inspect the seal washer for any signs of damage.
  3. Inspect the A/C refrigerant components for damage or burrs. Repair or replace as necessary.
  4. NOTE: DO NOT reuse sealing washer. Discard the sealing washer.

Scheme 20

Scheme 20: Installation Procedure
Scheme 20: Installation Procedure
  1. NOTE: Flat washer type seals do not require lubrication. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
  2. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
  3. Carefully install the new seal washer onto the A/C refrigerant component.
  4. The washer must completely bottom against the surface of the fitting.
  5. NOTE: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.

Scheme 21

Scheme 21: Removal Procedure
Scheme 21: Removal 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. NOTE: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. Cap or tape the A/C refrigerant components.
  6. Discard the O-ring seal.

Scheme 22

Scheme 22: Installation Procedure
Scheme 22: Installation Procedure

Scheme 23

Scheme 23
Scheme 23
  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. NOTE: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
  5. NOTE: DO NOT reuse O-ring seals. 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.

Scheme 24

Scheme 24: Removal Procedure
Scheme 24: Removal Procedure

Scheme 25

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Scheme 27

Scheme 27
Scheme 27
  1. Recover the refrigerant from the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR)»(ref-652243-S08177155752014082300000)
  2. Remove the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000)
  3. Remove the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT (LAU)»(ref-652236-S23821398762014082300000) or «AIR CLEANER ASSEMBLY REPLACEMENT (LF1)»(ref-652236-S23083372802014082300000) .
  4. Remove the radiator air lower deflector. Refer to «RADIATOR AIR LOWER DEFLECTOR REPLACEMENT»(ref-652246-S08001852322014082300000)
  5. Remove the air conditioning condenser and air conditioning evaporator tube nut (1) at thermal expansion valve.
  6. Remove the air conditioning condenser and air conditioning evaporator tube (2) from thermal expansion valve.
  7. Remove the air conditioning condenser and air conditioning evaporator tube nut (1) at condenser.
  8. Remove the air conditioning condenser and air conditioning evaporator tube (2) from condenser.
  9. Remove the air conditioning condenser and evaporator hose nut (1) at air conditioning condenser and air conditioning evaporator tube.
  10. Remove the air conditioning condenser and evaporator hose (2) from air conditioning condenser and air conditioning evaporator tube
  11. Remove the air conditioning condenser and air conditioning evaporator tube nut (1) at the frame rail.
  12. Disengage tube retainers from body.
  13. Remove the air conditioning condenser and air conditioning evaporator tube (2) from vehicle.

Scheme 28

Scheme 28: Installation Procedure
Scheme 28: Installation Procedure

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31
  1. Install the air conditioning condenser and air conditioning evaporator tube (2) to the vehicle.
  2. Engage tube retainers from body.
  3. Refer to «FASTENER CAUTION»(ref-652229-S20487768742014082300000) . Install the air conditioning condenser and air conditioning evaporator tube nut (1) at the frame rail and tighten to. 15 Nm (11 lb in) .
  4. Install the air conditioning condenser and evaporator hose (2) from air conditioning condenser and air conditioning evaporator tube
  5. Install the air conditioning condenser and evaporator hose nut (1) at air conditioning condenser and air conditioning evaporator tube and tighten to 15 Nm (11 lb in) .
  6. Install the air conditioning condenser and air conditioning evaporator tube (2) from condenser.
  7. Install the air conditioning condenser and air conditioning evaporator tube nut (1) on the condenser and tighten to 15 Nm (11 lb in) .
  8. Install the air conditioning condenser and air conditioning evaporator tube (2) from thermal expansion valve.
  9. Install the air conditioning condenser and air conditioning evaporator tube nut (1) on the thermal expansion valve and tighten to 15 Nm (11 lb in) .
  10. Install the radiator air lower deflector. Refer to «RADIATOR AIR LOWER DEFLECTOR REPLACEMENT»(ref-652246-S08001852322014082300000)
  11. Install the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT (LAU)»(ref-652236-S23821398762014082300000) or «AIR CLEANER ASSEMBLY REPLACEMENT (LF1)»(ref-652236-S23083372802014082300000)
  12. Install the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000)
  13. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR)»(ref-652243-S08177155752014082300000)

Scheme 32

Scheme 32: Removal Procedure
Scheme 32: Removal Procedure

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34
  1. Recover the refrigerant from the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR)»(ref-652243-S08177155752014082300000)
  2. Raise and support the vehicle. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT (LAU)»(ref-652236-S23821398762014082300000) or «AIR CLEANER ASSEMBLY REPLACEMENT (LF1)»(ref-652236-S23083372802014082300000)
  3. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-652246-S16212509752014082300000)
  4. Disconnect the air conditioning pressure sensor electrical connector.
  5. Remove the air conditioning condenser and evaporator hose bolt (1) at the compressor.
  6. Remove the air conditioning condenser and evaporator hose (2) from the compressor.
  7. Remove the air conditioning condenser and evaporator hose nut (1) at air conditioning condenser and air conditioning evaporator tube.
  8. Remove the air conditioning condenser and evaporator hose (2) from air conditioning condenser and air conditioning evaporator tube.
  9. Remove the air conditioning condenser and evaporator hose nut (1) at the condenser.
  10. Remove the air conditioning condenser and evaporator hose (2) from the condenser.
  11. Remove the air conditioning condenser and evaporator hose (2) from vehicle.
  12. Remove and discard all sealing washers.
  13. Transfer the air conditioning pressure sensor if necessary.

Scheme 35

Scheme 35: Installation Procedure
Scheme 35: Installation Procedure

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37
  1. Install new sealing washers. Refer to «AIR CONDITIONING SYSTEM SEAL REPLACEMENT»(ref-652243-S16357935682014082300000)
  2. Install the air conditioning condenser and evaporator hose (2) to the condenser.
  3. Refer to «FASTENER CAUTION»(ref-652229-S20487768742014082300000) . Install the air conditioning condenser and evaporator tube nut (1) on the condenser and tighten to 15 Nm (11 lb in) .
  4. Install the air conditioning condenser and evaporator hose (2) to the air conditioning condenser and air conditioning evaporator tube.
  5. Install the air conditioning condenser and evaporator hose nut (1) at air conditioning condenser and air conditioning evaporator tube and tighten to 15 Nm (11 lb in) .
  6. Install the air conditioning condenser and evaporator hose (2) to the compressor.
  7. Install the air conditioning condenser and evaporator tube nut (1) on the compressor and tighten to 15 Nm (11 lb in) .
  8. Connect the air conditioning pressure sensor electrical connector.
  9. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-652246-S16212509752014082300000)
  10. Lower the vehicle.
  11. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR)»(ref-652243-S08177155752014082300000)

Scheme 38

Scheme 38: Removal Procedure
Scheme 38: Removal Procedure

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40
  1. Recover the refrigerant from the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR)»(ref-652243-S08177155752014082300000)
  2. Raise and support the vehicle. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT (LAU)»(ref-652236-S23821398762014082300000) or «AIR CLEANER ASSEMBLY REPLACEMENT (LF1)»(ref-652236-S23083372802014082300000)
  3. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-652246-S16212509752014082300000)
  4. Remove the air conditioning condenser and evaporator hose bolt (1) at the compressor.
  5. Remove the air conditioning condenser and evaporator hose (2) from the compressor.
  6. Remove the air conditioning condenser and evaporator hose nut (1) at air conditioning condenser and air conditioning evaporator tube.
  7. Remove the air conditioning condenser and evaporator hose (2) from air conditioning condenser and air conditioning evaporator tube.
  8. Remove the air conditioning condenser and evaporator hose nut (1) at the condenser.
  9. Remove the air conditioning condenser and evaporator hose (2) from the condenser.
  10. Remove the air conditioning condenser and evaporator hose (2) from vehicle.
  11. Remove and discard all sealing washers.

Scheme 41

Scheme 41: Installation Procedure
Scheme 41: Installation Procedure

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43
  1. Install new sealing washers. Refer to «AIR CONDITIONING SYSTEM SEAL REPLACEMENT»(ref-652243-S16357935682014082300000)
  2. Install the air conditioning condenser and evaporator hose (2) to the condenser.
  3. Refer to «FASTENER CAUTION»(ref-652229-S20487768742014082300000) . Install the air conditioning condenser and evaporator tube nut (1) on the condenser and tighten to 15 Nm (11 lb in) .
  4. Install the air conditioning condenser and evaporator hose (2) to the air conditioning condenser and air conditioning evaporator tube.
  5. Install the air conditioning condenser and evaporator hose nut (1) at air conditioning condenser and air conditioning evaporator tube and tighten to 15 Nm (11 lb in) .
  6. Install the air conditioning condenser and evaporator hose (2) to the compressor.
  7. Install the air conditioning condenser and evaporator tube nut (1) on the compressor and tighten to 15 Nm (11 lb in) .
  8. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-652246-S16212509752014082300000)
  9. Lower the vehicle.
  10. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR)»(ref-652243-S08177155752014082300000)
  1. GE 50078 Electronic Leak Detector
  2. GE 46246 Valve Core Tool

For equivalent regional tools. Refer to SPECIAL TOOLS

Scheme 44

Scheme 44: Removal Procedure
Scheme 44: Removal Procedure
  1. Recover the refrigerant from the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR)»(ref-652243-S08177155752014082300000)
  2. Using the GE 46246 Valve Core Tool, remove the valve core from the service port.

Scheme 45

Scheme 45: Installation Procedure
Scheme 45: Installation Procedure
  1. Install the valve core to the service port.
  2. Refer to «FASTENER CAUTION»(ref-652229-S20487768742014082300000) Using the GE 46246 Valve Core Tool, tighten the valve core to 11 Nm (97 lb in) .
  3. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR)»(ref-652243-S08177155752014082300000)
  4. Leak test the fittings of the component using the GE 50078 Electronic Leak Detector.

Scheme 46

Scheme 46: Receiver and Dehydrator Replacement
Scheme 46: Receiver and Dehydrator Replacement
CalloutComponent Name
Preliminary Procedure Remove the air conditioner condenser. Refer to CONDENSER REPLACEMENT (LF1) or CONDENSER REPLACEMENT (LAU) .
1Receiver and Dehydrator Bracket Blot. Refer to FASTENER CAUTION . Tighten 6 Nm(53 lb in)
2Receiver and Dehydrator Bracket
3Receiver and Dehydrator Bolt Tighten 6 Nm(53 lb in)
4Receiver and Dehydrator Procedure Remove and discard the O ring seal. Refer to AIR CONDITIONING O-RING SEAL REPLACEMENT

Scheme 47

Scheme 47: Air Conditioning Evaporator Thermal Expansion Valve Replacement
Scheme 47: Air Conditioning Evaporator Thermal Expansion Valve Replacement
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR) . Remove the air conditioning condenser and air conditioning evaporator tube from the TXV valve. Refer to AIR CONDITIONING CONDENSER AND AIR CONDITIONING EVAPORATOR TUBE REPLACEMENT .
1Thermal Expansion Valve Bolt (Qty: 2) Refer to FASTENER CAUTION . Tighten 6 Nm(53 lb in)
2Thermal Expansion Valve NOTE: Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
NOTE
Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .

Scheme 48

Scheme 48: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LF1)
Scheme 48: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LF1)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR) . Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT
1A/C Refrigerant Pressure Sensor Refer to FASTENER CAUTION . Tighten 5 Nm (44 lb in)

Scheme 49

Scheme 49: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LAU)
Scheme 49: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR) . Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT
1A/C Refrigerant Pressure Sensor Refer to FASTENER CAUTION . Tighten 5 Nm (44 lb in)

Scheme 50

Scheme 50: Evaporator Air Temperature Sensor Replacement
Scheme 50: Evaporator Air Temperature Sensor Replacement
CalloutComponent Name
Preliminary Procedures Remove the instrument panel compartment. Refer to INSTRUMENT PANEL COMPARTMENT REPLACEMENT . Reposition any wiring or hoses to gain access to evaporator temperature sensor.
1Evaporator Temperature Sensor Procedure Disconnect the wiring connector Rotate sensor 1/4 turn counter clock wise to remove

Scheme 51

Scheme 51: Air Conditioning Condenser Replacement (LF1)
Scheme 51: Air Conditioning Condenser Replacement (LF1)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR) Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT Remove the radiator air side baffles. Refer to RADIATOR AIR SIDE BAFFLE REPLACEMENT - LEFT SIDE and RADIATOR AIR SIDE BAFFLE REPLACEMENT - RIGHT SIDE Remove the air conditioning condenser and air conditioning evaporator hose tube. Refer to AIR CONDITIONING CONDENSER AND AIR CONDITIONING EVAPORATOR TUBE REPLACEMENT Remove the air conditioning condenser and evaporator hose. Refer to HOSE REPLACEMENT (LF1) or HOSE REPLACEMENT (LAU) .
1Air Conditioning Condenser Bolts (Qty 2) Refer to FASTENER CAUTION . Tighten 9 Nm (80 lb in)
2Air Conditioning Condenser NOTE: The air condition condenser is removed through the bottom.
NOTE
The air condition condenser is removed through the bottom.

Scheme 52

Scheme 52: Air Conditioning Condenser Replacement (LAU)
Scheme 52: Air Conditioning Condenser Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR) Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT Remove the radiator air side baffle and deflector. Refer to RADIATOR AIR SIDE BAFFLE REPLACEMENT - LEFT SIDE and RADIATOR AIR SIDE BAFFLE REPLACEMENT - RIGHT SIDE Remove the air conditioning condenser and air conditioning evaporator hose tube. Refer to AIR CONDITIONING CONDENSER AND AIR CONDITIONING EVAPORATOR TUBE REPLACEMENT Remove the air conditioning condenser and evaporator hose. Refer to HOSE REPLACEMENT (LF1) or HOSE REPLACEMENT (LAU) .
1Air Conditioning Condenser Bolts (Qty 2) Refer to FASTENER CAUTION . Tighten 9 Nm (80 lb in)
2Air Conditioning Condenser NOTE: The air condition condenser is removed through the bottom.
NOTE
The air condition condenser is removed through the bottom.

Scheme 53

Scheme 53: Heater and Air Conditioning Evaporator Module Replacement
Scheme 53: Heater and Air Conditioning Evaporator Module Replacement
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING (BELT DRIVEN COMPRESSOR) . Remove the heater inlet hose from the heater core tube. Refer to HOSE REPLACEMENT (LF1) or HOSE REPLACEMENT (LAU) . Remove the heater outlet hose from the heater core tube. Refer to HOSE REPLACEMENT (LF1) or HOSE REPLACEMENT (LAU) . Remove the instrument panel tie bar. Refer to INSTRUMENT PANEL TIE BAR REPLACEMENT .
1Heater and Air Conditioning Evaporator and Blower Module Fastener Refer to FASTENER CAUTION . Procedure With the aid of an assistant, remove the heater and air conditioning evaporator and blower module from the vehicle. Tighten 1.4 Nm (12 lb in)

Scheme 54

Scheme 54: Air Conditioning Evaporator Replacement
Scheme 54: Air Conditioning Evaporator Replacement
CalloutComponent Name
Preliminary Procedures Remove the heater and air conditioning evaporator and blower module. Refer to HEATER AND AIR CONDITIONING EVAPORATOR MODULE REPLACEMENT . Disconnect the heater and air conditioning evaporator and blower module assembly electrical connectors.
1Remove Heater Core Screw and Bracket Refer to FASTENER CAUTION . Tighten 2.5 Nm (23 lb in)
2Remove Heater Core retainer screw Procedure Pull out the heater core. Tighten 2.5 Nm (23 lb in)
3Heater and Blower and Air Conditioning Control Module Refer to HEATER AND AIR CONDITIONING REMOTE CONTROL REPLACEMENT .
4A/C Evaporator Thermal Expansion Valve Fastener (Qty: 2) Tighten 5 Nm (53 lb in)
5Air Conditioning Evaporator Thermal Expansion Valve Procedure Remove and discard sealing washers.
6Heater and Air Conditioning Evaporator and Blower Module Case Screw (Qty: 11) Tighten 1.5 Nm (9 lb in)
7Heater and Air Conditioning Evaporator and Blower Module Lower Case
8Air Conditioning Evaporator Core

Scheme 55

Scheme 55: Air Conditioning Evaporator and Blower Case Drain Replacement
Scheme 55: Air Conditioning Evaporator and Blower Case Drain Replacement
PosComponent Name
Preliminary Procedures Remove the front floor console extension. Refer to FRONT FLOOR CONSOLE EXTENSION REPLACEMENT .
1Evaporator Case Drain Procedure Remove the evaporator case drain.

Scheme 56

Scheme 56: Air Conditioning Evaporator and Blower Module Drain Hose Replacement
Scheme 56: Air Conditioning Evaporator and Blower Module Drain Hose Replacement
CalloutComponent Name
Preliminary Procedure Remove Front Floor Console Extension Cover. Refer to
1Air Conditioning Evaporator and Blower Module Drain Hose Procedure Loosen the carpet in the range of the front floor console. Release and pull off the drain hose from the HVAC module assembly and unsnap the drain fitting grommet from the front floor panel.

BO 38185 Hose Clamp Pliers

For equivalent regional tools. Refer to SPECIAL TOOLS

Scheme 57

Scheme 57: Removal Procedure
Scheme 57: Removal Procedure

Scheme 58

Scheme 58
Scheme 58
  1. Drain the cooling system. Refer to «DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) , «DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) , or «DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .
  2. Remove the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000)
  3. Disengage tension on the heater inlet hose clamp (1) at the engine using BO 38185 Hose Clamp Pliers.
  4. Remove the heater inlet hose (2) from the engine.
  5. Release the clip from the quick disconnect (1) and remove the heater inlet hose (2) from the heater core tube.
  6. Remove the heater inlet hose from the vehicle.

Scheme 59

Scheme 59: Installation Procedure
Scheme 59: Installation Procedure

Scheme 60

Scheme 60
Scheme 60
  1. Install heater inlet hose to the vehicle.
  2. NOTE: Lubricate the inside diameters of the hose with clean coolant prior to installation. Install the heater inlet hose (2) to the heater core.
  3. Install the heater inlet hose (2) to the engine.
  4. Engage tension on the heater inlet hose clamp (1) at the engine using BO 38185 Hose Clamp Pliers.
  5. Install the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000)
  6. Fill the cooling system. Refer to «DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) , «DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) , or «DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .

BO 38185 Hose Clamp Pliers

For equivalent regional tools. Refer to SPECIAL TOOLS

Scheme 61

Scheme 61: Removal Procedure
Scheme 61: Removal Procedure

Scheme 62

Scheme 62
Scheme 62
  1. Drain the cooling system. Refer to «DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) , «DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) , or «DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .
  2. Remove the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000)
  3. Disengage tension on the heater inlet hose clamp (1) at the engine using BO 38185 Hose Clamp Pliers.
  4. Remove the heater inlet hose (2) from the engine.
  5. Release the clip from the quick disconnect (1) and remove the heater inlet hose (2) from the heater core tube.
  6. Remove the heater inlet hose from the vehicle.

Scheme 63

Scheme 63: Installation Procedure
Scheme 63: Installation Procedure

Scheme 64

Scheme 64
Scheme 64
  1. Install heater inlet hose to the vehicle.
  2. NOTE: Lubricate the inside diameters of the hose with clean coolant prior to installation. Install the heater inlet hose (2) to the heater core.
  3. Install the heater inlet hose (2) to the engine.
  4. Engage tension on the heater inlet hose clamp (1) at the engine using BO 38185 Hose Clamp Pliers.
  5. Install the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000)
  6. Fill the cooling system. Refer to «DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) , «DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) , or «DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .

BO 38185 Hose Clamp Pliers

For equivalent regional tools. Refer to SPECIAL TOOLS

Scheme 65

Scheme 65: Removal Procedure
Scheme 65: Removal Procedure

Scheme 66

Scheme 66
Scheme 66
  1. Drain the cooling system. Refer to «DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) , «DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) , or «DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .
  2. Remove the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000)
  3. Disengage tension on the heater outlet hose clamp (1) at the engine using BO 38185 Hose Clamp Pliers.
  4. Remove the heater outlet hose (2) from the engine.
  5. Release the clip from the quick disconnect (1) and remove the heater outlet hose (2) from the heater core tube.
  6. Remove the heater outlet hose from the vehicle.

Scheme 67

Scheme 67: Installation Procedure
Scheme 67: Installation Procedure

Scheme 68

Scheme 68
Scheme 68
  1. Install heater outlet hose to the vehicle.
  2. NOTE: Lubricate the inside diameters of the hose with clean coolant prior to installation. Install the heater outlet hose (2) to the heater core.
  3. Install the heater outlet hose (2) to the engine.
  4. Disengage tension on the heater outlet hose clamp (1) at the engine using BO 38185 Hose Clamp Pliers.
  5. Install the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000)
  6. Fill the cooling system. Refer to «DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) , «DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) , or «DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .

BO 38185 Hose Clamp Pliers

For equivalent regional tools. Refer to SPECIAL TOOLS

Scheme 69

Scheme 69: Removal Procedure
Scheme 69: Removal Procedure

Scheme 70

Scheme 70
Scheme 70
  1. Drain the cooling system. Refer to «DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) , «DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) , or «DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .
  2. Remove the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000)
  3. Disengage tension on the heater outlet hose clamp (1) at the engine using BO 38185 Hose Clamp Pliers.
  4. Remove the heater outlet hose (2) from the engine.
  5. Release the clip from the quick disconnect (1) and remove the heater outlet hose (2) from the heater core tube.
  6. Remove the heater outlet hose from the vehicle.

Scheme 71

Scheme 71: Installation Procedure
Scheme 71: Installation Procedure

Scheme 72

Scheme 72
Scheme 72
  1. Install heater outlet hose to the vehicle.
  2. NOTE: Lubricate the inside diameters of the hose with clean coolant prior to installation. Install the heater outlet hose (2) to the heater core.
  3. Install the heater outlet hose (2) to the engine.
  4. Disengage tension on the heater outlet hose clamp (1) at the engine using BO 38185 Hose Clamp Pliers.
  5. Install the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000)
  6. Fill the cooling system. Refer to «DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) , «DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) , or «DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .

Scheme 73

Scheme 73: Heater Core Outlet Tube Replacement
Scheme 73: Heater Core Outlet Tube Replacement
CalloutComponent Name
Preliminary Procedure Remove the heater and air conditioning evaporator case. Refer to HEATER AND AIR CONDITIONING EVAPORATOR MODULE REPLACEMENT .
1Heater Outlet Tube Boot
2Bracket Heater Core Outlet Tube Bolt Refer to FASTENER CAUTION . Tighten 2.5 Nm (23 lb in)
3Heater Core Outlet Tube Brace
4Heater Core Outlet Tube Clamp
5Heater Core Outlet Tube

Scheme 74

Scheme 74: Heater Core Inlet Tube Replacement
Scheme 74: Heater Core Inlet Tube Replacement
CalloutComponent Name
Preliminary Procedure Remove the heater and air conditioning evaporator case. Refer to HEATER AND AIR CONDITIONING EVAPORATOR MODULE REPLACEMENT .
1Heater Outlet Tube Boot
2Bracket Heater Core Inlet Tube Bolt Refer to FASTENER CAUTION . Tighten 2.5 Nm (23 lb in)
3Heater Core Outlet Tube Brace
4Heater Core Outlet Tube Clamp
5Heater Core Outlet Tube

Scheme 75

Scheme 75: Passenger Compartment Air Filter Replacement
Scheme 75: Passenger Compartment Air Filter Replacement
CalloutComponent Name
Preliminary Procedures Remove the instrument panel compartment. Refer to INSTRUMENT PANEL COMPARTMENT REPLACEMENT .
1Passenger Compartment Air Filter Service Lid. Procedure Release the retainer and open the service lid.
2Passenger Compartment Air Filter Lid
3Passenger Compartment Air Filter

Scheme 76

Scheme 76: Air Inlet Housing Replacement
Scheme 76: Air Inlet Housing Replacement
CalloutComponent Name
Preliminary Procedures Remove the heater and air conditioning evaporator and blower module. Refer to HEATER AND AIR CONDITIONING EVAPORATOR MODULE REPLACEMENT . Disconnect the electrical connectors as necessary.
1Air Inlet Housing Fastener (Qty: 4) Refer to FASTENER CAUTION . Tighten 2.5 Nm (23 lb in)
2Air Inlet Housing

Scheme 77

Scheme 77: Blower Motor Control Module Replacement
Scheme 77: Blower Motor Control Module Replacement
CalloutComponent Name
Preliminary Procedures Remove the instrument panel compartment. Refer to INSTRUMENT PANEL COMPARTMENT REPLACEMENT . Disconnect the heater and blower and air conditioning control module electrical connectors.
1Heater and Blower and Air Conditioning Control Module Screws (Qty: 2) Refer to FASTENER CAUTION . Tighten 1.5 Nm (13 lb in)
2Heater and Blower and Air Conditioning Control Module

Scheme 78

Scheme 78: Blower Motor Replacement
Scheme 78: Blower Motor Replacement
CalloutComponent Name
Preliminary Procedures Remove the right-hand side instrument panel insulator panel. Refer to INSTRUMENT PANEL INSULATOR PANEL REPLACEMENT - RIGHT SIDE . Disconnect the blower motor electrical connector.
1Blower Motor Fastener (Qty: 3) Refer to FASTENER CAUTION . Tighten 1.7 Nm (15 lb in)
2Blower Motor

Scheme 79

Scheme 79: Air Distributor Duct Replacement
Scheme 79: Air Distributor Duct Replacement
CalloutComponent Name
Preliminary Procedures Remove the Instrument panel assembly. Refer to INSTRUMENT PANEL ASSEMBLY REMOVAL . Reposition any wiring or hoses to gain access to air duct.
1Air Distributor Duct Screw (Qty: 6) Tighten 1.5 Nm (13.2 lb in)
2Air Distributor Duct

Scheme 80

Scheme 80: Instrument Panel Outer Air Outlet Replacement - Left Side
Scheme 80: Instrument Panel Outer Air Outlet Replacement - Left Side
CalloutComponent Name
Preliminary Procedure Remove the instrument panel cluster trim plate cover assembly. Refer to INSTRUMENT PANEL CLUSTER TRIM PLATE COVER REPLACEMENT .
1Instrument Panel Outer Air Outlet Fastener Refer to FASTENER CAUTION .
2Instrument Panel Outer Air Outlet Assembly Procedure Grasp the outlet assembly and pull straight outward releasing the retainer clips securing the outlet to the instrument panel assembly.

Scheme 81

Scheme 81: Instrument Panel Center Air Outlet Replacement
Scheme 81: Instrument Panel Center Air Outlet Replacement
CalloutComponent Name
Preliminary Procedure Remove the instrument panel cluster trim plate cover assembly. Refer to INSTRUMENT PANEL CLUSTER TRIM PLATE COVER REPLACEMENT .
1Instrument Panel Center Air Outlet Fastener Refer to FASTENER CAUTION .
2Instrument Panel Center Air Outlet Assembly Procedure Grasp the outlet assembly and pull straight outward releasing the retainer clips securing the outlet to the instrument panel assembly.

Scheme 82

Scheme 82: Instrument Panel Outer Air Outlet Replacement - Right Side
Scheme 82: Instrument Panel Outer Air Outlet Replacement - Right Side
PosComponent Name
1Preliminary procedures Remove the instrument panel compartment. See INSTRUMENT PANEL COMPARTMENT REPLACEMENT .
2Instrument Panel Outer Air Outlet Assembly, screw Procedure Use a flat bladed plastic trim tool in order to release the retainer clip securing the left inboard edge of the outlet assembly. Pull the outlet slightly to the left releasing the retainer tab securing the right outer board edge of the outlet to the instrument panel assembly.

Scheme 83

Scheme 83: Instrument Panel Outer Air Outlet Deflector Replacement - Left Side
Scheme 83: Instrument Panel Outer Air Outlet Deflector Replacement - Left Side
CalloutComponent Name
Preliminary Procedure Remove the left instrument panel side trim panel. Refer to INSTRUMENT PANEL SIDE TRIM PANEL REPLACEMENT . Remove the left windshield garnish molding. Refer to WINDSHIELD GARNISH MOLDING REPLACEMENT .
1Instrument Panel Outer Air Outlet Deflector Fastener Refer to FASTENER CAUTION .
2Instrument Panel Outer Air Outlet Deflector Assembly

Scheme 84

Scheme 84: Instrument Panel Outer Air Outlet Deflector Replacement - Right Side
Scheme 84: Instrument Panel Outer Air Outlet Deflector Replacement - Right Side
CalloutComponent Name
Preliminary Procedure Remove the instrument panel trim panel assembly. Refer to INSTRUMENT PANEL ASSEMBLY REMOVAL .
1Instrument Panel Outer Air Outlet Deflector Fastener Refer to FASTENER CAUTION .
2Instrument Panel Outer Air Outlet Deflector Assembly

Scheme 85

Scheme 85: Instrument Panel Compartment Air Duct Replacement
Scheme 85: Instrument Panel Compartment Air Duct Replacement
CalloutComponent Name
Preliminary Procedure Remove the instrument panel compartment. Refer to INSTRUMENT PANEL COMPARTMENT REPLACEMENT .
1Instrument Panel Compartment Air Duct NOTE: Pull the duct from the HVAC module.
NOTE
Pull the duct from the HVAC module.

Scheme 86

Scheme 86: Floor Front Air Outlet Duct Replacement
Scheme 86: Floor Front Air Outlet Duct Replacement
CalloutComponent Name
Preliminary Procedures Remove the front floor console. Refer to FLOOR FRONT AIR OUTLET DUCT REPLACEMENT .
1Front Floor Console Front Air Duct (Qty: 3) Procedure Disconnect and transfer sensor on left duct, if equipped.

Scheme 87

Scheme 87: Floor Front Air Outlet Duct Replacement - Right Side
Scheme 87: Floor Front Air Outlet Duct Replacement - Right Side
CalloutComponent Name
Preliminary Procedures Remove the instrument panel compartment. Refer to INSTRUMENT PANEL COMPARTMENT REPLACEMENT .
1Floor Air Outlet Duct Fastener (Qty: 3) Refer to FASTENER CAUTION .
2Floor Air Outlet Duct

Scheme 88

Scheme 88: Floor Front Air Outlet Duct Replacement - Left Side
Scheme 88: Floor Front Air Outlet Duct Replacement - Left Side
CalloutComponent Name
Preliminary Procedures Remove the instrument panel insulator panel - left side. Refer to INSTRUMENT PANEL INSULATOR PANEL REPLACEMENT - LEFT SIDE . Remove the instrument panel lower trim panel. Refer to INSTRUMENT PANEL LOWER TRIM PANEL REPLACEMENT - LEFT SIDE .
1Floor Air Outlet Duct Retainer (Qty: 4)
2Floor Air Outlet Duct

Scheme 89

Scheme 89: Front Floor Console Front Air Duct Replacement
Scheme 89: Front Floor Console Front Air Duct Replacement
CalloutComponent Name
Preliminary Procedures Remove the front floor console. Refer to FLOOR FRONT AIR OUTLET DUCT REPLACEMENT .
1Front Floor Console Front Air Duct (Qty: 3) Procedure Disconnect and transfer sensor on left duct, if equipped.

Scheme 90

Scheme 90: Front Floor Console Rear Air Duct Replacement
Scheme 90: Front Floor Console Rear Air Duct Replacement
CalloutComponent Name
Preliminary Procedures Remove the front floor console. Refer to FLOOR FRONT AIR OUTLET DUCT REPLACEMENT .
1Front Floor Rear Air Duct (Qty: 3) Disconnect and transfer sensor on left duct, if equipped.

Scheme 91

Scheme 91: Windshield Defroster Nozzle Grille Replacement
Scheme 91: Windshield Defroster Nozzle Grille Replacement
CalloutComponent Name
1Windshield Defroster Nozzle Grille Assembly Procedure Use a flat bladed plastic trim tool in order to release the retainer clips securing the windshield defroster nozzle grille to the instrument panel assembly.

Scheme 92

Scheme 92: Windshield Defroster Nozzle Replacement
Scheme 92: Windshield Defroster Nozzle Replacement
CalloutComponent Name
Preliminary Procedures Remove the Instrument panel assembly. Refer to INSTRUMENT PANEL ASSEMBLY REMOVAL . Remove the air distributor duct. Refer to AIR DISTRIBUTOR DUCT REPLACEMENT
1Windshield Defroster Nozzle Duct Fasteners (Qty: 8) Refer to FASTENER CAUTION .
2Windshield Defroster Nozzle Duct

Scheme 93

Scheme 93: Side Window Defogger Outlet Duct Replacement - Left Side
Scheme 93: Side Window Defogger Outlet Duct Replacement - Left Side
CalloutComponent Name
Preliminary Procedures Remove the Instrument panel assembly. Refer to INSTRUMENT PANEL ASSEMBLY REMOVAL .
1Side Window Defogger Outlet Duct-Left Procedure Remove the Windshield Defroster Nozzle Duct Replacement. Refer to WINDSHIELD DEFROSTER NOZZLE REPLACEMENT Remove the Side Window Defogger Outlet Duct-Left. Remove the Side Window Defogger Outlet Duct from vehicle.

Scheme 94

Scheme 94: Side Window Defogger Outlet Duct Replacement - Right Side
Scheme 94: Side Window Defogger Outlet Duct Replacement - Right Side
CalloutComponent Name
Preliminary Procedures Remove the Instrument panel assembly. Refer to INSTRUMENT PANEL ASSEMBLY REMOVAL .
1Side Window Defogger Outlet Duct-Right Procedure Remove the Windshield Defroster Nozzle Duct Replacement. Refer to WINDSHIELD DEFROSTER NOZZLE REPLACEMENT Remove the Side Window Defogger Outlet Duct-Right. Remove the Side Window Defogger Outlet Duct from vehicle.

Scheme 95

Scheme 95: Floor Rear Air Outlet Duct Replacement
Scheme 95: Floor Rear Air Outlet Duct Replacement
PosComponent Name
Preliminary Procedures Remove Front Floor Console Rear Air Outlet. Refer to FLOOR FRONT AIR OUTLET DUCT REPLACEMENT .
1Front Floor Rear Air Duct (Qty: 3) Correction Disconnect and transfer sensor on left duct, if equipped.

Scheme 96

Scheme 96: Floor Rear Air Outlet Duct Replacement - Left Side
Scheme 96: Floor Rear Air Outlet Duct Replacement - Left Side
CalloutComponent Name
Preliminary Procedures Remove the front floor carpet. Refer to FRONT FLOOR PANEL CARPET REPLACEMENT .
1Front Floor Air Outlet Duct
2Rear Floor Air Outlet Duct

Scheme 97

Scheme 97: Floor Rear Air Outlet Duct Replacement - Right Side
Scheme 97: Floor Rear Air Outlet Duct Replacement - Right Side
CalloutComponent Name
Preliminary Procedures Remove the front floor carpet. Refer to FRONT FLOOR PANEL CARPET REPLACEMENT .
1Front Floor Air Outlet Duct
2Rear Floor Air Outlet Duct

Scheme 98

Scheme 98: Mode Control Cam Actuator Replacement
Scheme 98: Mode Control Cam Actuator Replacement
CalloutComponent Name
Preliminary Procedures Disconnect the negative battery cable. Refer to: BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION . Remove LH floor air outlet duct. Refer to FLOOR REAR AIR OUTLET DUCT REPLACEMENT - LEFT SIDE .
1Mode Cam Actuator Cover Screw (Qty: 1) Refer to FASTENER CAUTION . Procedure Disconnect the mode actuator electrical connector. Tighten 1.5 Nm (13 lb in)
2Mode Cam Actuator Cover.
3Mode Cam Actuator Gears
4Mode Cam Actuator Screw (Qty: 2) Tighten 1.5 Nm (13 lb in)
5Mode Cam Actuator NOTE: Actuator is self-calibrating when connecting the battery.
NOTE
Actuator is self-calibrating when connecting the battery.

Scheme 99

Scheme 99: Heater Core Replacement
Scheme 99: Heater Core Replacement
CalloutComponent Name
Preliminary Procedures Remove the left-hand side instrument panel insulator panel. Refer to INSTRUMENT PANEL INSULATOR PANEL REPLACEMENT - LEFT SIDE . Remove the instrument panel (I/P) lower trim panel. Refer to INSTRUMENT PANEL LOWER TRIM PANEL REPLACEMENT - LEFT SIDE . Remove the heater inlet hose from the heater core tube. Refer to HOSE REPLACEMENT (LF1) or HOSE REPLACEMENT (LAU) . Remove the heater outlet hose from the heater core tube. Refer to HOSE REPLACEMENT (LF1) or HOSE REPLACEMENT (LAU) .
1Heater Core Tube Clamp (Qty: 2)
2Heater Core Tube Assembly NOTE: Coolant may still be in the heater core, collect coolant or blow out heater core with compressed air.
3Heater Core Tube Seal (Qty: 2)
4Heater Core Bracket Fastener Refer to FASTENER CAUTION . Tighten 1.4 Nm (12 lb in)
5Heater Core Procedure Pull out the heater core.
NOTE
Coolant may still be in the heater core, collect coolant or blow out heater core with compressed air.

Scheme 100

Scheme 100: Auxiliary Air Conditioning Blower Motor Replacement
Scheme 100: Auxiliary Air Conditioning Blower Motor Replacement
CalloutComponent Name
Preliminary Procedure Remove the Floor console. Refer to FRONT FLOOR CONSOLE REPLACEMENT . Disconnect all electrical connector. Remove front floor air outlet duct. Refer to FLOOR FRONT AIR OUTLET DUCT REPLACEMENT Remove the blower motor bracket fastener at bottom of blower assembly.
1Auxiliary Blower Motor Fastener (Qty: 9) Refer to FASTENER CAUTION . Tighten 2.5 Nm (23 lb in)
2Auxiliary Blower Motor

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