Heating, Ventilation, and Air Conditioning: Removal & Installation Saab 9-7X I

Installation Procedure

1. Add the proper amount of polyalkylene glycol (PAG) oil to the compressor crankcase. Refer to «Compressor Oil Balancing»(ref-268096-S18976932182007101800000) .
2. Position the A/C compressor mounting bracket partially into the vehicle.
3. Position the A/C compressor partially into the vehicle. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the upper compressor mounting bolts into the compressor mounting bracket. Tighten: Tighten the upper rear bolts to 50 N.m (37 lb ft).
5. Install the upper compressor mounting bolts (4) into the compressor and bracket assembly.
6. Position the compressor and bracket assembly into the correct location on the engine.
7. Tighten the upper compressor mounting bolts (4). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
8. Raise the vehicle
9. Start the lower compressor mounting bolts (3). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
10. Connect the electrical connector to the A/C compressor.
11. Raise the vehicle.
12. Install the lower coolant hose. Refer to «Radiator Inlet Hose Replacement (LH6)»(ref-268147-S38942730032007101800000) or «Radiator Inlet Hose Replacement (LL8)»(ref-268147-S29361189922007101800000) .
13. Install the compressor hose assembly. Refer to «Compressor Hose Assembly Replacement (LH6)»(ref-268096-S15574468532007101800000) or «Compressor Hose Assembly Replacement (LL8)»(ref-268096-S24271056052007101800000) .
14. Install the heater hoses. Refer to «Heater Inlet Hose Replacement (LL8)»(ref-268096-S30877658262007101800000) or «Heater Inlet Hose Replacement (LH6)»(ref-268096-S26675446392007101800000) and «Heater Hose Replacement - Outlet (LH6)»(ref-268096-S28417121532007101800000) or «Heater Hose Replacement - Outlet (LL8)»(ref-268096-S06323324822007101800000) .
15. Install the accessory drive belt to the tensioner.
16. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
17. Install the washer solvent container. Refer to «Washer Solvent Container Replacement»(ref-268104-S07078591782007101800000) .
18. Fill the cooling system. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .
19. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
20. Leak test the fittings of the component using the J 39400-A . See «Special Tools»(ref-268096-S29609511412007101800000) .

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

Scheme 56

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. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.
5. Cap or tape the A/C refrigerant components.
6. Discard the O-ring seal.

Scheme 57

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. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system.
4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. IMPORTANT: DO NOT reuse O-ring seals.
5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
6. The O-ring seal must be fully seated.
7. Assemble the A/C components. Refer to the appropriate repair procedure. For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification.

1. Install the compressor hose assembly.
2. Install the compressor hose to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-268096-S12742096462007101800000) . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the compressor hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
4. Connect the electrical connector to the A/C low pressure switch.
5. Install the compressor hose to the accumulator using new sealing washers. Refer to «Sealing Washer Replacement»(ref-268096-S12742096462007101800000) .
6. Install the nut (1) to the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
7. Install the compressor hose (1) to the A/C compressor using new sealing washers. Refer to «Sealing Washer Replacement»(ref-268096-S12742096462007101800000) .
8. Install the compressor hose nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
9. Install the washer bottle. Refer to «Washer Solvent Container Replacement»(ref-268104-S07078591782007101800000) .
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
11. Leak test the fittings of the component using J 39400-A . See «Special Tools»(ref-268096-S29609511412007101800000) .

1. Install new O-ring seals. Refer to «O-Ring Replacement»(ref-268096-S42294676402007101800000) .
2. Install the compressor discharge hose (2) to the condenser (4). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the compressor discharge hose nut. Tighten: Tighten the hose nut to 28 N.m (21 lb ft).
4. Install the compressor hose to the connector through the driver wheel opening.
5. Install the nut. Tighten: Tighten the nut to 48 N.m (35 lb ft).
6. Install the compressor suction hose to the stud on the engine.
7. Install the nut. Tighten: Tighten the nut to 48 N.m (35 lb ft).
8. Install the compressor suction hose to the engine lift bracket.
9. Install the bolt. Tighten: Tighten the bolt to 48 N.m (35 lb ft).
10. Connect the compressor suction hose (1) to the accumulator.
11. Install the compressor suction hose nut to the accumulator. Tighten: Tighten the nut to 48 N.m (35 lb ft).
12. Install the sealing washers. Refer to «Sealing Washer Replacement»(ref-268096-S12742096462007101800000) .
13. Connect the compressor hose assembly hose to the compressor (4).
14. Install the compressor hose assembly washers.
15. Install the retaining nut (3). Tighten: Tighten the nut to 33 N.m (24 lb ft).
16. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
17. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-268096-S29609511412007101800000) .

Evaporator Tube Replacement

Tools Required

1. J 26549-E Orifice Tube Remover. See «Special Tools»(ref-268096-S29609511412007101800000) .
2. J 39400-A Halogen Leak Detector. See «Special Tools»(ref-268096-S29609511412007101800000) .

Scheme 58

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
2. Loosen the evaporator tube (5) from the evaporator.
3. Loosen the auxiliary evaporator tube (7) from the auxiliary piping.
4. Remove the evaporator tube nut from the condenser.
5. Remove the nuts (1, 2) retaining the evaporator tube to the fender.
6. Remove the washer solvent container. Refer to «Washer Solvent Container Replacement»(ref-268104-S07078591782007101800000) .
7. Remove the coolant recovery tank. Refer to «Coolant Recovery Reservoir Replacement»(ref-268147-S12769490242007101800000) .
8. Remove the evaporator tube using J 26549-E . See «Special Tools»(ref-268096-S29609511412007101800000) .
9. Remove the O-ring seal and discard.

1. Install the new O-ring seal. Refer to «O-Ring Replacement»(ref-268096-S42294676402007101800000) .
2. Install the evaporator tube.
3. Connect the evaporator tube to the evaporator (5). Tighten: Tighten the nut to 28 N.m (21 lb ft).
4. Connect the auxiliary evaporator tube to the auxiliary piping. Tighten: Tighten the nut to 28 N.m (21 lb ft).
5. Connect the evaporator tube to the condenser. Tighten: Tighten the nut to 28 N.m (21 lb ft).
6. Install the coolant recovery tank. Refer to «Coolant Recovery Reservoir Replacement»(ref-268147-S12769490242007101800000) .
7. Install the washer solvent container. Refer to «Washer Solvent Container Replacement»(ref-268104-S07078591782007101800000) .
8. Install the nuts (1, 2) retaining the evaporator tube to the fender. Tighten: Tighten the nuts to 28 N.m (21 lb ft).
9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
10. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-268096-S29609511412007101800000) .

Expansion (Orifice) Tube Replacement

Tools Required

1. J 26549-E Orifice Tube Remover. See «Special Tools»(ref-268096-S29609511412007101800000) .
2. J 39400-A Halogen Leak Detector. See «Special Tools»(ref-268096-S29609511412007101800000) .

Scheme 59

Scheme 60

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
2. Remove the accumulator. Refer to «Accumulator Replacement»(ref-268096-S21231262572007101800000) .
3. Remove the coolant reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-268147-S12769490242007101800000) .
4. Remove the evaporator tube nut (3) at the evaporator (1).
5. Remove the evaporator tube (4) from the evaporator (1).
6. Remove the O-ring seal and discard.
7. Remove the nut from the evaporator tube block fitting.
8. Separate the evaporator tubes (4, 6) at the block fitting.
9. Use the J 26549-E in order to remove the expansion tube. See «Special Tools»(ref-268096-S29609511412007101800000) .
10. Remove the expansion tube from the evaporator tube (6).

1. Use the J 26549-E in order to install the expansion tube. See «Special Tools»(ref-268096-S29609511412007101800000) . IMPORTANT: Install the shorter screen end of the expansion tube into the evaporator tube (6) first.
2. Install the new O-ring seal. Refer to «O-Ring Replacement»(ref-268096-S42294676402007101800000) .
3. Assemble the evaporator tubes (4, 6). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the evaporator tube nut. Tighten: Tighten the nut to 28 N.m (21 lb ft).
5. Connect the evaporator tube (4) to the evaporator (1).
6. Install the nut (3). Tighten: Tighten the nut to 28 N.m (21 lb ft).
7. Install the coolant reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-268147-S12769490242007101800000) .
8. Install the accumulator. Refer to «Accumulator Replacement»(ref-268096-S21231262572007101800000) .
9. Recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
10. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-268096-S29609511412007101800000) .

Scheme 61

1. Remove the protective cover from the underhood fuse block.
2. Remove the compressor relay (1) from the underhood fuse block (2).

1. Install the compressor relay (1) to the underhood fuse block (2).
2. Install the protective hood to the underhood fuse block.

1. Install the new O-ring seal. Refer to «O-Ring Replacement»(ref-268096-S42294676402007101800000) . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the A/C low pressure switch (2) to the accumulator (1). Tighten: Tighten the A/C low pressure switch to 4.8 N.m (42 lb in).
3. Connect the A/C low pressure switch electrical connector.
4. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-268096-S29609511412007101800000) .

Scheme 62

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Disconnect the electrical connector from the A/C refrigerant pressure sensor. The connector is accessible through the lower control arm.
3. Remove the A/C refrigerant pressure sensor from the compressor hose block.
4. Remove and discard the O-ring seal from the A/C refrigerant pressure sensor.

1. Install the new O-ring seal. Refer to «O-Ring Replacement»(ref-268096-S42294676402007101800000) .
2. Install the A/C refrigerant pressure sensor to the compressor hose block. Tighten: Tighten the A/C refrigerant pressure sensor to 4.8 N.m (42 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Connect the electrical connector to the A/C refrigerant pressure sensor.
4. Leak test the fittings of the component using J 39400-A . See «Special Tools»(ref-268096-S29609511412007101800000) .
5. Lower the vehicle.

1. Install the condenser to the radiator. IMPORTANT: If replacing the condenser, add the refrigerant oil to the condenser. Refer to «Refrigerant System Capacities»(ref-268096-S08144962772007101800000) for the capacity information. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the condenser to the radiator bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
3. Install the condenser LH upper bracket bolt and bracket. Tighten: Tighten the bolt to 9 N.m (80 lb in).
4. Install the studs from the condenser inlet and outlets. Tighten: Tighten the studs to 4.5 N.m (40 lb in).
5. Install the evaporator tube (4) from the condenser.
6. Install the evaporator tube nut (5) form the condenser. Tighten: Tighten the nut to 28 N.m (21 lb in).
7. Install the upper radiator support bar.
8. Install the bolts form the upper radiator support bar. Tighten: Tighten the bolts to 50 N.m (37 lb in).
9. Install the radiator diagonal base. Refer to «Radiator Support Diagonal Brace Replacement»(ref-268102-S15556797092007101800000) .
10. Install the head lamp housing panel. Refer to «Headlamp Housing Panel Replacement»(ref-268090-S02626798062007101800000) .
11. Install the hood latch. Refer to «Hood Replacement»(ref-268102-S04771574792007101800000) .
12. Connect the compressor discharge hose (2) to the condenser.
13. Install the compressor discharge hose nut (1) to the condenser. Tighten: Tighten the nut to 28 N.m (210 lb in).
14. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
15. Leak test the fittings of the components using J 39400-A . See «Special Tools»(ref-268096-S29609511412007101800000) .

1. Install the accumulator to the vehicle. IMPORTANT: If replacing the accumulator, add the refrigerant oil to the accumulator. Refer to «Refrigerant System Capacities»(ref-268096-S08144962772007101800000) for the capacity information.
2. Install the accumulator into the accumulator clamp. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the accumulator clamp nut. Tighten: Tighten the nut to 10 N.m (88 lb in).
4. Install the A/C low pressure switch. Tighten: Tighten the A/C low pressure switch to 5 N.m (44 lb in).
5. Install new O-ring seals. Refer to «O-Ring Replacement»(ref-268096-S42294676402007101800000) .
6. Install the accumulator to the evaporator.
7. Install the accumulator retaining nut. Tighten: Tighten the nut to 28 N.m (21 lb ft).
8. Connect the compressor suction hose to the accumulator (4).
9. Install the suction hose nut. Tighten: Tighten the nut to 48 N.m (35 lb ft).
10. Connect the electrical connector to the A/C low pressure switch.
11. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
12. Leak test the fitting of the component using the J 39400-A . See «Special Tools»(ref-268096-S29609511412007101800000) .

HVAC Module Assembly Replacement

Tools Required

1. J 43181 Heater Line Quick Connect Release Tool. See «Special Tools»(ref-268096-S29609511412007101800000) .
2. J 39400-A Halogen Leak Detector. See «Special Tools»(ref-268096-S29609511412007101800000) .

Removal Procedure

1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
3. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel Carrier Replacement»(ref-268082-S09046931932007101800000) .
4. Reposition the heater hose clamps using J 43181 . See «Special Tools»(ref-268096-S29609511412007101800000) .
5. Disconnect the heater hoses from the heater core.
6. Remove the retaining nut (3) from the accumulator (6) at the evaporator (1).
7. Disconnect the accumulator (6) from the evaporator (1).
8. Disconnect the evaporator tube (4) from the evaporator (1).
9. Disconnect all of the electrical connectors to the HVAC module assembly.
10. Remove the HVAC module assembly.

Scheme 63

1. If replacing the HVAC module assembly (8), transfer the components from the old HVAC module assembly as necessary.
2. Install the HVAC module assembly (8).
3. Connect all of the electrical connectors to the HVAC module assembly.
4. Connect the heater hoses to the heater core.
5. Connect the evaporator tube (4) to the evaporator (1).
6. Install the accumulator (6) to the evaporator (1). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
7. Tighten the accumulator retaining nut. Tighten: Tighten the nut to 4.5 N.m (40 lb in).
8. Install the I/P carrier. Refer to «Instrument Panel Carrier Replacement»(ref-268082-S09046931932007101800000) .
9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
10. Leak test the fittings of the components using the J 39400-A . See «Special Tools»(ref-268096-S29609511412007101800000) .
11. Refill the engine coolant. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .

Scheme 64

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-268096-S41266174542007101800000) . IMPORTANT: Some screws are hidden under the foam insulation.
2. Remove the screws to separate the HVAC module assembly halves.
3. Separate the HVAC module assembly (1).
4. Remove the evaporator core (2) from the HVAC module assembly (1).
5. Remove the seal between the HVAC module assembly halves.

1. Install the seal between the HVAC module assembly halves.
2. Install the evaporator core (2) to the HVAC module assembly (1). IMPORTANT: Ensure that the seal between the 2 case sections is in place.
3. Assemble the HVAC module assembly. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the screws to join the HVAC module assembly halves. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-268096-S41266174542007101800000) .

Heater Inlet Hose Replacement (LL8)

Tools Required

1. J 43181 Heater Line Quick Connect Release Tool. See «Special Tools»(ref-268096-S29609511412007101800000) .
2. GE-47622 Hose Clamp Pliers. See «Special Tools»(ref-268096-S29609511412007101800000) .

Scheme 65

1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .
2. Using the J 43181 , disconnect the inlet heater hose (2) from the heater core inlet tube. See «Special Tools»(ref-268096-S29609511412007101800000) . Install the J 43181 to the quick connect on the outlet heater core hose (2). See «Special Tools»(ref-268096-S29609511412007101800000) . Close the tool around the inlet heater core hose. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose (2). Pull the heater hose forward in order to disengage the hose from the heater core.
3. Position the inlet heater hose clamp (1) at the engine block using GE-47622 . See «Special Tools»(ref-268096-S29609511412007101800000) .
4. Remove the heater inlet hose (2) from the inlet hose fitting at the engine block.
5. Remove the heater inlet hose.

1. Apply coolant to the end of the heater inlet hose. IMPORTANT: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block.
2. Install the heater inlet hose (2) to the inlet hose fitting at the engine block.
3. Position the inlet heater hose clamp (1) at the engine block using GE-47622 . See «Special Tools»(ref-268096-S29609511412007101800000) .
4. Install the quick connect end of the outlet heater core hose (2) to the heater core.
5. Fill the engine cooling system. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .

Scheme 66

Heater Inlet Hose Replacement (LH6)

Scheme 67

Heater Hose Replacement - Outlet (LH6)

Heater Hose Replacement - Outlet (LL8)

Tools Required

1. J 43181 Heater Line Quick Connect Release Tool. See «Special Tools»(ref-268096-S29609511412007101800000) .
2. GE-47622 Hose Clamp Pliers. See «Special Tools»(ref-268096-S29609511412007101800000) .

Scheme 68

Scheme 69

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .
2. Remove the transmission. Refer to «Transmission Replacement (LL8)»(ref-268097-S42661221372007101800000) or «Transmission Replacement (LM4)»(ref-268097-S27748498692007101800000) .
3. Remove the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-268108-S11577458102007101800000) or «Generator Replacement (5.3L Engine)»(ref-268108-S14779794212007101800000) .
4. Using the J 43181 , disconnect the outlet hose from the heater core outlet tube (1). See «Special Tools»(ref-268096-S29609511412007101800000) . Install the J 43181 to the outlet heater core hose. See «Special Tools»(ref-268096-S29609511412007101800000) . Close the tool around the outlet heater core hose. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
5. Remove the heater outlet hose (3) from the heater core (1).
6. Position the outlet heater hose clamp (6) at the water pump using GE-47622 . See «Special Tools»(ref-268096-S29609511412007101800000) .
7. Remove the heater outlet hose (7) from the outlet hose fitting.
8. Remove the heater outlet hose.

1. Install the outlet heater hose.
2. Install the heater outlet hose (7) to the outlet hose fitting.
3. Position the outlet heater hose clamp (6) at the outlet hose fitting using GE-47622 . See «Special Tools»(ref-268096-S29609511412007101800000) .
4. Install the heater outlet hose (3) to the heater core (1).
5. Firmly push the quick connect onto the heater core hose until you hear an audible click.
6. Install the transmission. Refer to «Transmission Replacement (LL8)»(ref-268097-S42661221372007101800000) or «Transmission Replacement (LM4)»(ref-268097-S27748498692007101800000) .
7. Install the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-268108-S11577458102007101800000) or «Generator Replacement (5.3L Engine)»(ref-268108-S14779794212007101800000) .
8. Fill the cooling system. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .

1. Remove the cover of the under hood fuse block.
2. Remove the blower motor relay (1) from the under hood fuse block (2).

1. Install the blower motor relay (1) to the under hood fuse block.
2. Install the cover of the under hood fuse block.

Scheme 70

1. Remove the right closeout/insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(ref-268082-S19340635172007101800000) .
2. Disconnect the blower motor resistor electrical connector (3).
3. Remove the blower motor resistor mounting screws (2).
4. Remove the blower motor resistor (1).

1. Install the blower motor resistor (1). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the blower motor resistor mounting screws (2). Tighten: Tighten the screws to 1.9 N.m (17 lb in).
3. Connect the blower motor resistor electrical connector (3).
4. Install the right closeout/insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(ref-268082-S19340635172007101800000) .

Scheme 71

1. Remove the right closeout/insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(ref-268082-S19340635172007101800000) .
2. Remove the instrument panel (I/P) storage compartment door. Refer to «Instrument Panel Compartment Door Replacement»(ref-268082-S04714731232007101800000) .
3. Disconnect the blower motor electrical connector.
4. Remove the blower motor mounting screws.
5. Remove the blower motor cooling tube.
6. Remove the blower motor (2).

1. Install the blower motor (2).
2. Install the blower motor cooling tube. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the blower motor mounting screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
4. Connect the blower motor electrical connector.
5. Install the right closeout/insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(ref-268082-S19340635172007101800000) .

Scheme 72

1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(ref-268082-S34606562722007101800000) .
2. Remove the driver side air distributor duct screws.
3. Remove the air distributor duct (1) from the I/P.
4. Unclip the radio antenna wire from the duct.
5. Remove the air temperature sensor from the duct.

1. Install the air distributor duct (1) to I/P. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the retaining screws to the air distributor duct. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
3. Install the air temperature sensor to the air distributor duct.
4. Clip the radio antenna wire to the duct.
5. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(ref-268082-S34606562722007101800000) .

Scheme 73

Scheme 74

Scheme 75

1. Using a flat-bladed tool, release the left housing retaining pin and gently push the left side of the air outlet into the housing assembly.
2. With the air outlet in the housing assembly, rotate the air outlet face down.
3. Using a flat bladed tool, remove the left side of the air outlet from the housing assembly.
4. Remove the air outlet from the housing assembly.

1. Position the air outlet face down at the housing opening.
2. Position the right side of the air outlet below the housing retaining pin.
3. Seat the right side of the air outlet to the housing retaining pin by lifting upward.
4. Seat the left side of the air outlet to the housing retaining pin.
5. Rotate the air outlet upward past the detent position.
6. Adjust the air outlet to the original position.

Scheme 76

Scheme 77

Scheme 78

1. Remove the left closeout/insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-268082-S30513740912007101800000) .
2. Remove the knee bolster trim panel. Refer to «Driver Knee Bolster Panel Replacement»(ref-268082-S23797171272007101800000) .
3. Remove the instrument panel (I/P) cluster bezel, Chevrolet only. Refer to «Instrument Panel Cluster Trim Plate Bezel Replacement»(ref-268082-S31534364022007101800000) .
4. Remove the radio. Refer to «Radio Replacement»(ref-268083-S03817611892007101800000) .
5. Remove the 2 screws (1) from the bottom of the air outlet assembly.
6. Remove the air deflectors from the outlet. Refer to «Air Outlet Replacement - Instrument Panel»(ref-268096-S05978870342007101800000) .
7. Grasp and pull the outlet rearward from the I/P.
8. Remove the outlet from the vehicle.

1. If reinstalling the original outlet, install the air deflectors in the outlet. Refer to «Air Outlet Replacement - Instrument Panel»(ref-268096-S05978870342007101800000) .
2. Install the outlet assembly to the I/P.
3. Install the 2 retaining screws (1). Tighten: Tighten the screws to 2.5 N.m (22 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the radio. Refer to «Radio Replacement»(ref-268083-S03817611892007101800000) .
5. Install the I/P cluster bezel, Chevrolet only. Refer to «Instrument Panel Cluster Trim Plate Bezel Replacement»(ref-268082-S31534364022007101800000) .
6. Install the knee bolster trim panel. Refer to «Driver Knee Bolster Panel Replacement»(ref-268082-S23797171272007101800000) .
7. Install the left closeout/insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-268082-S30513740912007101800000) .

Scheme 79

Scheme 80

Scheme 81

1. Remove the right instrument panel (I/P) access cover.
2. Remove the screw (1) retaining the air outlet assembly to the I/P.
3. Grasp and pull the outlet assembly rearward from the I/P.
4. Remove the outlet assembly from the vehicle.

1. Install the outlet assembly to the I/P.
2. Install the retaining screw. Tighten: Tighten the screw to 2.5 N.m (22 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the I/P access cover.

Scheme 82

Scheme 83

1. Remove the console support bracket. Refer to «Floor Console Bracket Replacement»(ref-268082-S17522422122007101800000) .
2. Drill the pop rivet (1).
3. Rotate the air outlet duct (3) to remove the duct from the console support bracket (1).
4. Remove the air outlet duct from the vehicle.

1. Install the air outlet duct (3) to the console support bracket (1).
2. Install a new pop rivet (1).
3. Install the console support bracket. Refer to «Floor Console Bracket Replacement»(ref-268082-S17522422122007101800000) .

Scheme 84

Scheme 85

1. Remove the instrument panel (I/P) trim pad. Refer to «Instrument Panel Upper Trim Pad Replacement»(ref-268082-S27918195722007101800000) .
2. Remove the retaining screw (4) from the side window defroster duct (3).
3. Remove the passenger side window defroster duct.
4. Remove the air distribution duct.
5. Release locking tabs (2) from the defroster duct (1).
6. Remove the defroster duct (1).

1. Install the defroster duct.
2. Insert defroster duct into retaining slots.
3. Install the retaining screw (4) to the passenger side window defroster duct (3). Tighten: Tighten the nut to 2 N.m (18 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the I/P assembly. Refer to «Instrument Panel Carrier Replacement»(ref-268082-S09046931932007101800000) .

Scheme 86

1. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel Carrier Replacement»(ref-268082-S09046931932007101800000) .
2. Remove the push pin (2) retaining the floor air outlet duct (1) to the heater module.
3. Remove the floor duct (1).

1. Install the floor air outlet duct (1) into position. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the floor air outlet duct retaining push pin (2). Tighten: Tighten the screws to 1.9 N.m (17 lb in).
3. Install the I/P carrier. Refer to «Instrument Panel Carrier Replacement»(ref-268082-S09046931932007101800000) .

Scheme 87

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-268096-S41266174542007101800000) .
2. Remove the floor air outlet duct retaining screws (2, 3, 4).
3. Remove the RH side floor air outlet duct (1).

1. Install the floor air outlet duct (1) into position. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the floor air outlet duct retaining screws (2, 3, 4). Tighten: Tighten the screws to 1.9 N.m (17 lb in).
3. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-268096-S41266174542007101800000) .

Scheme 88

1. Remove the HVAC module assembly (1). Refer to «HVAC Module Assembly Replacement»(ref-268096-S41266174542007101800000) .
2. Remove screws in order to separate the HVAC module assembly.
3. Remove the screws from the air temperature actuator.
4. Remove the air temperature actuator.
5. Remove the screws from the mode actuator.
6. Remove the mode actuator.
7. Separate the HVAC module case halves.
8. Remove the air temperature door (1) from the lower module half.

1. Install the air temperature door (1) to the lower module half.
2. Assemble the HVAC module case halves.
3. Install the mode actuator. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the screws to the mode actuator. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
5. Install the air temperature actuator.
6. Install the screws to the air temperature actuator. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
7. Install the screws in order to assemble the HVAC module. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
8. Install the HVAC module assembly (1). Refer to «HVAC Module Assembly Replacement»(ref-268096-S41266174542007101800000) .

Scheme 89

Scheme 90

1. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel Carrier Replacement»(ref-268082-S09046931932007101800000) .
2. Remove the screws from the defroster actuator.
3. Remove the defroster actuator.
4. Remove screws in order to separate the defroster/mode outlet cover (2) from the HVAC module assembly (1).
5. Remove the defroster/mode outlet cover.
6. Remove the defroster door (1) from the HVAC module assembly.

1. Install the defroster door (1) to the HVAC module assembly.
2. Install the defroster/mode outlet cover.
3. Install the defroster/mode outlet cover screws to the HVAC module assembly (1). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the screws to assemble the defroster/mode outlet to the HVAC module assembly. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
5. Install the defroster actuator.
6. Install the screws to the defroster actuator. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
7. Install the I/P carrier. Refer to «Instrument Panel Carrier Replacement»(ref-268082-S09046931932007101800000) .

Scheme 91

1. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel Carrier Replacement»(ref-268082-S09046931932007101800000) .
2. Remove the screws from the mode actuator.
3. Remove the mode actuator.
4. Remove screws in order to separate the defroster/mode outlet cover (2) from the HVAC module assembly (1).
5. Remove the mode door (1) from the heater module.

1. Install the mode door (1) to the HVAC module assembly.
2. Install the defroster/mode outlet cover.
3. Install the defroster/mode outlet cover screws to the HVAC module assembly (1). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the screws to assemble the defroster/mode outlet to the HVAC module assembly. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
5. Install the mode actuator.
6. Install the screws to the mode actuator. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
7. Install the I/P carrier. Refer to «Instrument Panel Carrier Replacement»(ref-268082-S09046931932007101800000) .

Scheme 92

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-268096-S41266174542007101800000) .
2. Remove the screws retaining the recirculation assembly to the HVAC module assembly.
3. Remove the screws from the recirculation actuator.
4. Remove recirculation actuator.
5. Remove the recirculation door (1) from the recirculation assembly.

1. Install the recirculation door (1) to the recirculation assembly.
2. Install the recirculation actuator. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the screws to the recirculation actuator. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
4. Install the screws to assemble the recirculation assembly. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-268096-S41266174542007101800000) .

Scheme 93

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-268096-S41266174542007101800000) .
2. Remove the heater core access cover screws.
3. Remove the heater core access cover.
4. Remove the heater core (2) from the HVAC module assembly (1).

1. Install the heater core (2) to the HVAC module assembly (1).
2. Install the heater core access cover. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the heater core access cover screws. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
4. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-268096-S41266174542007101800000) .

Scheme 94

1. Remove the front floor console. Refer to «Console Replacement»(ref-268082-S14338351492007101800000) .
2. Disconnect the electrical connectors (4) from the blower motor-auxiliary (3).
3. Remove the air outlet duct from the blower motor-auxiliary.
4. Remove the screws (2, 5) from the blower motor-auxiliary.
5. Remove the blower motor-auxiliary (3).

1. Install the blower motor-auxiliary (3). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the retaining screws (2, 5) to the blower motor-auxiliary. Tighten: Tighten the screws to 10 N.m (88 lb in).
3. Install the air outlet duct to the blower motor-auxiliary.
4. Connect the electrical connectors (4) to the blower motor-auxiliary (3).
5. Install the front floor console. Refer to «Console Replacement»(ref-268082-S14338351492007101800000) .