Home ReviewsRefund Car not listed?
Home/Saturn/Astra/Saturn Astra I (2008-2009)/Repair manual/Automatic HVAC System/Heating, Ventilation, and Air Conditioning: Removal & Insta…
Contents Wiring diagrams Section: Automatic HVAC System All sections

Heating, Ventilation, and Air Conditioning: Removal & Installation Saturn Astra I

Automatic HVAC System 1 illustration ~5200 words

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  2. Disconnect the compressor refrigerant line. Remove the bolt (1).
  3. Raise the vehicle to full height.
  4. Remove the engine splash shield. Remove the 4 bolts. Open the 2 body-bound rivets.
  5. Relieve the pressure on the ribbed V-belt and remove from the compressor. Refer to «Drive Belt Replacement»(ref-302346-S09616944802008102100000) .
  6. Disconnect the wiring harness plug for the compressor. Release and disconnect the compressor wiring harness plug.
  7. Disconnect and remove the compressor from the main bracket. Remove the 3 bolts (1).

Installation Procedure

  1. Determine quantity of compressor lubricant and top up.
  2. Insert the compressor and attach to the main bracket. Tighten: Tighten the 3 bolts to 22 N.m (16 lb ft).
  3. Position the ribbed V-belt on the compressor. Refer to «Drive Belt Replacement»(ref-302346-S09616944802008102100000) .
  4. Connect the wiring harness plug for the compressor.
  5. Install the engine splash shield. Tighten: Tighten the 4 bolts to 8 N.m (70 lb in).
  6. Fasten the 2 body-bound rivets.
  7. Lower the vehicle to the ground.
  8. Install the refrigerant line to the compressor.
  9. Replace the 2 seal rings. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  10. Recharge the air conditioning system. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  1. Remove the compressor. Refer to «Air Conditioning Compressor Replacement»(ref-302297-S38287296112008102100000) .
  2. Remove the compressor clutch. Refer to «Compressor Clutch Assembly Replacement»(ref-302297-S34379967122008102100000) .
  3. Remove the retaining ring (1) from belt pulley.
  4. Pull off the compressor pulley (2).
  1. Install the compressor pulley on the compressor housing.
  2. Install the retaining ring in the groove in the compressor housing.
  3. Install the compressor clutch. Refer to «Compressor Clutch Assembly Replacement»(ref-302297-S34379967122008102100000) .
  4. Install the compressor. Refer to «Air Conditioning Compressor Replacement»(ref-302297-S38287296112008102100000) .
  1. Remove the compressor. Refer to «Air Conditioning Compressor Replacement»(ref-302297-S38287296112008102100000) .
  2. Clamp the compressor in a vice.
  3. Remove the compressor clutch. Remove the bolt. Counterhold with J 37872 /KM-806 (1). See «Special Tools»(ref-302297-S03187965892008102100000) . Remove the compressor clutch upwards.
  4. Remove the spacer washers.
  5. Remove the retaining ring (1) from belt pulley.
  6. Pull off the compressor pulley (2).
  1. Install the compressor pulley on the compressor housing.
  2. Install the retaining ring in the groove in the compressor housing.
  3. Install the compressor clutch. Insert the spacing washer. Press the compressor clutch into teeth on shaft. Tighten: Tighten the bolt to 12 N.m (106 lb in). Counterhold with J 37872 /KM-806 (1). See «Special Tools»(ref-302297-S03187965892008102100000) .
  4. Adjust the reference gap for the compressor clutch.
  5. Inspect reference gap of compressor clutch. Specification: Reference value: 0.3-0.7 mm (0.012-0.028 in).
  6. Correct the reference gap. Detach the compressor clutch. IMPORTANT: If the reference gap is too large, install thicker spacing washer (2) between compressor shaft and clutch, install a thinner one if the reference gap is too small. Spacing washers available: 0.1 mm, 0.3 mm, 0.5 mm. Set the reference gap.
  7. Repeat inspection as described.
  8. Remove the compressor from the vice.
  9. Install the compressor. Refer to «Air Conditioning Compressor Replacement»(ref-302297-S38287296112008102100000) .
  1. Remove the compressor. Refer to «Air Conditioning Compressor Replacement»(ref-302297-S38287296112008102100000) .
  2. Remove the compressor pulley. Refer to «Air Conditioning Compressor Pulley Replacement»(ref-302297-S35448204872008102100000) .
  3. Remove the clutch coil. Release the wiring harness for clutch coil of compressor (2). Remove the bolt. Remove the retaining ring (1). Remove the clutch coil off compressor.
  1. Install the clutch coil. Position the clutch coil. Insert the retaining ring. Connect the wiring harness. Tighten: Tighten the bolt to 4 N.m (35 lb in).
  2. Install the compressor pulley. Refer to «Air Conditioning Compressor Pulley Replacement»(ref-302297-S35448204872008102100000) .
  3. Install the compressor. Refer to «Air Conditioning Compressor Replacement»(ref-302297-S38287296112008102100000) .
  1. Drain the air conditioning system. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  2. Remove the high pressure relief valve. Remove the compressor relief valve (1). Remove the seal ring (2).
  1. Install the high pressure relief valve.
  2. Replace the seal ring. Before installation, coat seal ring with mineral oil. Tighten: Tighten the high pressure relief valve to 10 N.m (89 lb in).
  3. Evacuate and charge the air conditioning system. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  1. Remove the sealing washer from the A/C refrigerant component.
  2. Inspect the sealing washer for signs of damage to help determine the root cause of the failure.
  3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
  4. Discard the sealing washer.
  1. Inspect the new sealing washer for any signs of cracks, cuts, or damage. Do not use a damaged sealing 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 sealing washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting.
  5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair 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. Cap or tape the A/C refrigerant components.
  6. Discard the O-ring seal.
  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. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
  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. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  2. Disconnect the compressor hose at the compressor.
  3. Disconnect the compressor hose (1) from the condenser.
  4. Disconnect the compressor hose (1) from the evaporator hose.
  5. Remove the compressor hose assembly.
  1. Replace the seals on the compressor hose at the compressor.
  2. Install the compressor hose to the compressor. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  3. Install a new seal at the compressor hose joint.
  4. Connect the evaporator hose to the compressor hose. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  5. Install a new seal at the condenser.
  6. Install the compressor hose (1) to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  7. Recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  2. Disconnect the evaporator hose (2) at the condenser.
  3. Remove the right side engine damping block (1). Refer to «Engine Mount Replacement - Right Side»(ref-302346-S34402446832008102100000) .
  4. Disconnect the compressor hose (1) from the evaporator hose.
  5. Disconnect the evaporator hose at the thermal expansion valve (TXV).
  1. Install the evaporator hose to the vehicle.
  2. Install new seals to the evaporator hose at the TXV.
  3. Install the evaporator hose to the TXV. Tighten: Tighten the block connector bolt to 7 N.m (62 lb in).
  4. Install a new seal at the compressor hose joint.
  5. Connect the evaporator hose to the compressor hose (1). Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  6. Install a new seal to the evaporator hose.
  7. Install the evaporator hose (2) to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  8. Install the right side engine damping block (1). Refer to «Engine Mount Replacement - Right Side»(ref-302346-S34402446832008102100000) .
  9. Recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  2. Remove the service port valve core using J 46246 or equivalent. See «Special Tools»(ref-302297-S03187965892008102100000) .
  1. Install the service port valve core using J 46246 or equivalent. See «Special Tools»(ref-302297-S03187965892008102100000) . Tighten: Tighten the service port valve core to 2.5 N.m (22 lb in).
  2. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  3. Leak test the fittings using the J 39400-A .
  1. Remove the condenser. Refer to «Condenser Replacement»(ref-302297-S30017101002008102100000) .
  2. Remove the dryer insert (5).
  3. Remove the cover cap.
  4. Remove the bolt (1).
  5. Remove the retaining plate (2).
  6. Remove the dryer insert cover (3). If necessary use M6 bolt (4).
  7. Replace the sealing rings (6).
  1. Shorten dryer insert. Cut the dryer insert at notched point (arrow) using a suitable tool.
  2. Install the dryer insert.
  3. Install the dryer insert cover.
  4. Install the retaining plate. Install the bolt. Attach the cover cap.
  5. Install the condenser. Refer to «Condenser Replacement»(ref-302297-S30017101002008102100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  2. Remove the block connector, refrigerant lines, from expansion valve. Remove the bolt. Disconnect the refrigerant lines.
  3. Remove the thermostatically controlled expansion valve (TXV) (1). Insert the bolt, block connector refrigerant line, in expansion valve (2) and remove the expansion valve.
  1. Install the TXV. Use new sealing rings, before installation moisten only green colored sealing rings with mineral oil and insert. Install the service threaded rods (2) into retaining clip (1) to guide expansion valve. Push the expansion valve onto service threaded rods until the refrigerant lines lie in the expansion valve. Replace threaded rods in succession with fixing bolts. Tighten: Tighten the expansion valve bolts to 6 N.m (53 lb in).
  2. Install the block connector.
  3. Use the new sealing rings, before installation moisten only green colored sealing rings with mineral oil and insert. Tighten: Tighten the block connector bolt to 7 N.m (62 lb in).
  4. Recharge the air conditioning system. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  1. Disconnect the wiring harness plug for pressure sensor (1). Release and disconnect the wiring harness plug.
  2. Remove the pressure sensor (2).
  1. Install the pressure sensor.
  2. Replace the seal ring. Tighten: Tighten the pressure sensor to 10 N.m (89 lb in).
  3. Connect the wiring harness plug.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  2. Disconnect the wiring harness plug for pressure sensor (2). Release and disconnect the wiring harness plug.
  3. Detach the refrigerant lines from condenser. Remove the 2 bolts (3, 6).
  4. Remove the condenser. Cut the 4 cable ties (5). Remove the 4 bolts (1, 4).
  5. Remove the pressure sensor.
  1. Attach the pressure sensor to condenser.
  2. Replace the seal ring. Tighten: Tighten the pressure sensor to 10 N.m (89 lb in).
  3. Install the condenser. Tighten: Tighten the 4 bolts to 8 N.m (71 lb in). Fasten the 4 cable ties.
  4. Install the refrigerant lines to condenser. Tighten: Tighten the 2 bolts to 20 N.m (15 lb ft).
  5. Connect the wiring harness plug for pressure sensor.
  6. Recharge the air conditioning system. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  1. Remove the air inlet screen. Refer to «Air Inlet Screen Replacement»(ref-302297-S41681309192008102100000) .
  2. Remove the recirculating air valve housing, outside. Remove the 4 bolts (1). Remove the recirculating air valve housing grille (3). Remove the bolt for recirculating air valve housing (2).
  3. Remove the instrument panel (I/P) compartment. Remove the 4 bolts (1). Disconnect the wiring harness plug.
  4. Remove the inner paneling on I/P padding, lower passengers side. Remove the 2 bolts (3).
  5. Remove the air duct. Remove the body-bound rivet (2).
  6. Remove the heater fan motor (2). Disconnect the 2 wiring harness plugs (1) from series resistor. Remove the 5 bolts.
  7. For vehicles equipped with air conditioning (A/C), disconnect the wiring harness plug for the recirculating air valve (1) servo motor. Detach and remove the recirculating air valve housing (2). Remove the 2 bolts (3). Disconnect the wiring harness plug.
  1. For vehicles equipped with A/C, connect the wiring harness plug for recirculating air valve servo motor. Insert and tighten the recirculating air valve housing. Tighten: Tighten the 2 bolts to 5 N.m (44 lb in).
  2. Install the heater fan motor. Connect the clip. Install the 5 bolts. Connect the 2 wiring harness plugs.
  3. Install the air duct. Install the body-bound rivet.
  4. Install the I/P insulator panel. Install the 2 retainers.
  5. Install the recirculating air valve housing, outside. Tighten the bolt. Install the recirculating air valve housing grille. Tighten: Tighten the 4 bolts to 5 N.m (44 lb in).
  6. Install the air inlet screen. Refer to «Air Inlet Screen Replacement»(ref-302297-S41681309192008102100000) .
  1. For vehicles equipped with air conditioning (A/C) remove the block connector and the refrigerant lines from expansion valve. Remove the bolt. Detach the refrigerant lines.
  2. Remove the thermostatically controlled expansion valve (TXV) (1). Insert the bolt, block connector refrigerant line in the expansion valve (2) and remove the expansion valve.
  3. For vehicles equipped with A/C, remove the expansion valve retaining plate.
  4. Drain the coolant. Collect the coolant in a drip pan.
  5. Remove the condensation drain hose (1). Remove the 2 bolts.
  6. Disconnect the coolant hose. Detach the 2 coolant hoses. Release the 2 quick-release fittings.
  7. Remove the instrument panel (I/P) trim panel. Refer to «Instrument Panel Trim Panel Replacement»(ref-302290-S07544297022008102100000) .
  8. Remove the inflatable restraint I/P module. Refer to «Inflatable Restraint Instrument Panel Module Replacement»(ref-302295-S24043864612008102100000) .
  9. Remove the air inlet screen (1).
  10. Remove the windshield wiper arms (2). Remove the 2 covers. Remove the 2 nuts. Remove the 2 washers. Detach the 2 wiper arms from the shaft.
  11. Remove the air inlet screen (1). Lift the air inlet screen trim in dash area. IMPORTANT: Carefully release the clips from the dash bracket from inside outward. Release the 5 clips (3). Remove the hose (2) from the windshield washer system.
  12. Remove the air distributor housing from dash outside. Remove the 8 bolts.
  13. Disconnect the wiring harness plug from the fan series resistor (2). Disconnect the wiring harness plug. Release and disconnect the wiring harness plug.
  14. Remove the front floor console bracket (1) and (3). Remove the 2 bolts.
  15. Remove the I/P tie bar. Refer to «Instrument Panel Tie Bar Replacement»(ref-302290-S23894309972008102100000) .
  16. Remove the HVAC module assembly.
  1. With the aid of an assistant, insert the HVAC module assembly.
  2. Install the HVAC module assembly to the dash outside. Tighten: Tighten the 8 bolts to 10 N.m (89 lb in).
  3. Install the I/P tie bar. Refer to «Instrument Panel Tie Bar Replacement»(ref-302290-S23894309972008102100000) .
  4. Install the center I/P bracket. Tighten: Tighten the 2 bolts to 13 N.m (113 lb in).
  5. Install the inflatable restraint I/P module. Refer to «Inflatable Restraint Instrument Panel Module Replacement»(ref-302295-S24043864612008102100000) .
  6. Attach the coolant hoses to the heater core. Slide the 2 locks on the quick-release fittings in the arrow direction up to the stop. The plastic rings (green) are covered. Attach the 2 quick-release fittings on the heater core (1) connections up to the stop. Slide 2 locks (3) on the quick-release fittings in the arrow direction up to the stop. Note the markings applied. The plastic rings (green) must be visible. Inspect the correct seat of quick-release fittings and visibility of the plastic rings.
  7. Install the air inlet screen. Install the windshield washer hose. Install the 5 clips.
  8. Install the windshield wiper arms. Attach the 2 wiper arms to shaft. Install the 2 washers. Tighten: Tighten the 2 nuts to 17 N.m (13 lb ft). Install the 2 cover caps.
  9. Install the air inlet screen.
  10. Install the I/P trim panel. Refer to «Instrument Panel Trim Panel Replacement»(ref-302290-S07544297022008102100000) .
  11. Install the condensation drain. Tighten: Tighten the 2 bolts to 5 N.m (44 lb in).
  12. For vehicles equipped with A/C, insert the retaining plate expansion valve.
  13. For vehicles equipped with A/C, install the TXV. Use new sealing rings, before installation moisten only green colored sealing rings with mineral oil and insert. Install the service threaded rods (2) into the retaining clip (1) to guide expansion valve. Push the expansion valve onto service threaded rods until the refrigerant lines lie in the expansion valve. Replace the threaded rods in succession with fixing bolts. Tighten: Tighten the expansion valve bolts to 6 N.m (19 lb ft).
  14. Attach the block connector. Use new sealing rings, before installation moisten only green colored sealing rings with mineral oil and insert. Tighten: Tighten the block connector bolt to 7 N.m (62 lb in).
  15. For vehicles equipped with A/C, recharge and top up the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  16. Fill and bleed the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .
  17. Inspect the coolant system for leaks. Refer to «Cooling System Leak Testing»(ref-302344-S10139799192008102100000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  2. Remove the block connector and refrigerant lines from the expansion valve. Remove the bolt. Disconnect the refrigerant lines.
  3. Remove the thermostatically controlled expansion valve (TXV) (1). Insert the bolt, block connector refrigerant line, in expansion valve (2) and remove the expansion valve.
  4. Remove the expansion valve retaining plate.
  5. Remove the air inlet screen. Refer to «Air Inlet Screen Replacement»(ref-302297-S41681309192008102100000) .
  6. Remove the recirculating air valve housing, outside. Remove the 4 bolts (1). Remove the recirculating air valve housing grille (3). Remove the bolt for recirculating air valve housing (2).
  7. Remove the instrument panel (I/P) compartment. Remove the 4 bolts (1). Disconnect the wiring harness plug.
  8. Remove the insulator panel. Remove the 2 retainers (3).
  9. Remove the air duct. Remove the body-bound rivet (2).
  10. Remove the heater fan motor (2). Disconnect the 2 wiring harness plugs (1) from the series resistor. Release the clip. Remove the 5 bolts.
  11. Detach and remove the recirculating air valve housing (2). Remove the 2 bolts (3). Disconnect the wiring harness plug for mixed air valve servo motor. Release and disconnect the wiring harness plug.
  12. Remove the bolt for recirculating air valve housing Remove the bolt (2).
  13. Remove the pollen filter service flap and pollen filter. Remove the 3 bolts (3).
  14. Disconnect the radio cooling (1) and remove.
  15. Cut the air distributor housing. Cut the air distributor housing at groove (dotted line) using a suitable tool.
  16. Remove the evaporator core.
  1. Insert the evaporator core.
  2. Position the seal in the evaporator cover.
  3. Prepare the evaporator cover. Cut the 2 plastic webs (1) using a suitable tool.
  4. Connect the radio cooling to evaporator cover. Place the cut evaporator cover (1) on new cover (3), and use a pencil to mark the hole for radio cooling. Using a suitable tool, cut a hole (2) for radio cooling. Glue the radio cooling in place on both sides. Use adhesive mastic.
  5. Attach the evaporator cover. Install the radio cooling. Tighten: Tighten the 4 bolts to 2.5 N.m (22 lb in).
  6. Insert the pollen filter and attach pollen filter cover. Tighten: Tighten the 3 bolts to 2.5 N.m (22 lb in).
  7. Install the bolt for recirculating air valve housing.
  8. Insert and tighten the recirculating air valve housing. Tighten: Tighten the 2 bolts to 5 N.m (44 lb in).
  9. Connect the wiring harness plug to recirculating air valve servo motor.
  10. Install the heater fan motor. Connect the clip. Tighten: Tighten the 5 bolts to 8 N.m (71 lb in). Connect the 2 wiring harness plug.
  11. Install the retaining plate TXV.
  12. Install the air inlet screen. Refer to «Air Inlet Screen Replacement»(ref-302297-S41681309192008102100000) .
  13. Install the TXV. Use new sealing rings, before installation moisten only green colored sealing rings with mineral oil and insert. Install service threaded rods (2) into retaining clip (1) to guide expansion valve. Push expansion valve onto service threaded rods until the refrigerant lines lie in the expansion valve. Replace the threaded rods in succession with the fixing bolts. Tighten: Tighten the expansion valve to 6 N.m (53 lb in).
  14. Install the block connector.
  15. Use new seal rings, before installation moisten only green colored seal rings with mineral oil and insert. Tighten: Tighten the block connector bolt to 7 N.m (62 lb in).
  16. Install the air duct for footwell right side. Connect the clip.
  17. Install the I/P compartment.
  18. Connect the wiring harness plug. Tighten: Tighten the 4 bolts to 4 N.m (35 lb in).
  19. Install the insulator panel. Tighten the 2 retainers.
  20. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-302297-S08356516892008102100000) .
  1. Remove the drain hose from the dash.
  2. Remove the 2 bolts.

Note. Refer to Fastener Notice .

Install the drain hose to the dash.

Tighten: Tighten the 2 bolts to 5 N.m (44 lb in).

  1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .
  2. Lower the vehicle.
  3. Disconnect the heater hoses at the heater core (1).
  4. Reposition the heater hose clamps at the engine using SA9111E .
  5. Remove the heater hoses from the engine
  1. Install the heater hoses to the heater core. Slide the 2 locks on the quick-release fittings in the arrow direction up to the stop. Plastic rings (green) are covered. Install the 2 quick-release fittings on the heater core (1) connections up to the stop. Note the markings applied. Slide the 2 locks (3) on the quick-release fittings in the arrow direction up to the stop. Plastic rings (green) must be visible. Inspect the correct seat of quick-release fittings and visibility of the plastic rings, arrows.
  2. Install the hoses to the engine.
  3. Reposition the heater hose clamps to secure the hoses using SA9111E .
  4. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .
  1. Remove wind protection weatherstrip (1).
  2. Remove windshield wiper arms (2). Remove the 2 cover caps. Remove the 2 nuts. Remove the 2 washers. Pull the 2 windshield wiper arms from the shaft.
  3. Detach the air inlet screen (1). Lever off the air inlet screen in the dash area. Release the 5 clips (3). Detach the windshield washer hose (2).
  1. Install the air inlet screen. Attach the windshield washer hose. Install the 5 clips.
  2. Install the windshield wiper arms. Connect the 2 windshield wiper arms to the shafts. Install the 2 washers. Tighten: Tighten the 2 nuts to 17 N.m (13 lb ft). Install the 2 cover caps.
  3. Install the wind protection weatherstrip.
  1. Remove the instrument panel (I/P) compartment. Remove the 4 bolts (1). Disconnect the wiring harness plug.
  2. Remove the inner paneling on the I/P padding, lower passenger side. Remove the 2 bolts (3).
  3. Remove the passenger side footwell air duct.
  4. Remove the body-bound rivet (2).
  5. Remove the access panel for the passenger compartment air filter and remove the air filter (1) in the direction of the arrow. Remove the 3 bolts (2).
  1. Insert the air filter and attach the access panel for the air filter. Tighten: Tighten the 3 bolts to 5 N.m (44 lb in).
  2. Install the passenger side footwell air duct.
  3. Install the body-bound rivet.
  4. Install the I/P compartment.
  5. Connect the wiring harness plug. Tighten: Tighten the 4 bolts to 4 N.m (35 lb in).
  6. Install the inner paneling on I/P padding, lower passenger side. Tighten: Tighten the 2 bolts to 3 N.m (26 lb in).
  1. Remove the instrument panel (I/P) compartment. Remove the 4 bolts (1). Disconnect the wiring harness plug.
  2. Remove the series resistor (2) upwards from air distributor housing.
  3. Disconnect the resistor and fan motor wiring harness plugs. Disconnect and remove the 3 wiring harness plugs (1).
  4. Remove the resistor.
  1. Install the resistor.
  2. Connect the resistor and fan motor wiring harness plugs. Connect the 3 wiring harness plugs.
  3. Install the I/P compartment. Connect the wiring harness plug. Tighten: Tighten the 4 bolts to 4 N.m (35 lb in).
  1. Remove the instrument panel (I/P) compartment. Remove the 4 bolts (1). Disconnect the wiring harness plug.
  2. Remove the passenger side lower footwell trim. Remove the bolt (3).
  3. Remove the air duct. Remove the body-bound rivet (2).
  4. Remove the blower motor (2). Disconnect the 2 wiring harness plugs (1) from series resistor. Remove the 5 bolts.
  1. Install the blower motor. Connect the clip. Tighten: Tighten the 5 bolts to 6 N.m (63 lb in). Connect the 2 wiring harness plugs.
  2. Install the air duct. Install the body-bound rivet.
  3. Install the lower right footwell trim. Tighten: Tighten the bolt - pivot and lock.
  4. Install the I/P compartment. Connect the wiring harness plug. Tighten: Tighten the 4 bolts to 4 N.m (35 lb in).
  1. Remove the heating/air conditioning control. Refer to «Heater and Air Conditioning Control Replacement»(ref-302319-S11554297002008102100000) .
  2. Remove the accessory panel from the instrument panel (I/P). Remove the 2 bolts (1). Release the panel. Disconnect the wiring harness plug (2). Release and disconnect wiring harness plug.
  3. Remove the center air outlet (1). Release the 6 clips (2).
  1. Install the center air outlet. Install the 6 clips.
  2. Install the accessory panel onto the I/P.
  3. Connect the wiring harness plug. Clip in the panel. Tighten: Tighten the 2 bolts to 5 N.m (44 lb in).
  4. Install the heating/air conditioning control. Refer to «Heater and Air Conditioning Control Replacement»(ref-302319-S11554297002008102100000) .

Scheme 2

Scheme 2: Removal Procedure
Scheme 2: Removal Procedure
IMPORTANTRemove carefully from instrument panel (I/P) padding using a plastic wedge.

Remove the outer air outlet from the I/P padding.

Install the outer air outlet in the I/P padding.

  1. Remove the instrument panel (I/P) compartment. Remove the 4 bolts. Disconnect the wiring harness plug for the I/P compartment lighting.
  2. Remove the panel on I/P center trim panel. Refer to «Instrument Panel Center Trim Panel Replacement»(ref-302290-S05771727372008102100000) .
  3. Release and remove the air and radio cooling duct. Release the radio cooling duct (1) in the radio recess. Release and remove the air duct (2). Remove the air and radio cooling duct.
  4. If necessary, remove I/P compartment valve.
  1. If removed, install the I/P compartment valve.
  2. Install the air and radio cooling duct. Insert the air duct. Connect the air duct. Install the radio cooling duct in the radio recess.
  3. Install the I/P center trim panel. Refer to «Instrument Panel Center Trim Panel Replacement»(ref-302290-S05771727372008102100000) .
  4. Install the I/P compartment.
  5. Connect the wiring harness plug. Tighten: Tighten the 4 bolts to 4 N.m (35 lb in).
  1. Remove the front floor console. Refer to «Front Floor Console Replacement»(ref-302290-S10871999652008102100000) .
  2. Pull the rear footwell air outlet forward and remove.
  1. Insert the air outlet footwell at top and at the bottom, slide onto the air duct footwell rear.
  2. Install the front floor console. Refer to «Front Floor Console Replacement»(ref-302290-S10871999652008102100000) .
  1. Remove the instrument panel (I/P) trim panel. Refer to «Instrument Panel Trim Panel Replacement»(ref-302290-S07544297022008102100000) .
  2. Remove the defroster duct.
  1. Install the defroster duct.
  2. Install the I/P trim panel. Refer to «Instrument Panel Trim Panel Replacement»(ref-302290-S07544297022008102100000) .
  1. Remove the instrument panel (I/P) insulator panel. Remove the 2 retainers (1).
  2. Remove the floor air outlet duct (3). Remove the body-bound rivet (2).
  1. Install the floor air outlet duct. Install the body-bound rivet.
  2. Install the I/P insulator panel. Install the 2 retainers.
  1. Remove the instrument panel (I/P) compartment. Remove the 4 bolts (1). Disconnect the wiring harness plug.
  2. Remove the floor air outlet duct. Remove the body-bound rivet (2).
  1. Install the floor air outlet duct. Install the body-bound rivet.
  2. Install the I/P compartment. Install the 4 bolts Tighten: Tighten the 4 bolts to 4 N.m (35 lb in).
  3. Connect the wiring harness plug.
  1. Remove the front seat. Refer to «Front Seat Replacement - Bucket»(ref-302356-S37792874442008102100000) .
  2. Remove the front floor console. Refer to «Front Floor Console Replacement»(ref-302290-S10871999652008102100000) .
  3. Remove the door sill plate. Refer to «Door Sill Plate Replacement (Sedan)»(ref-302292-S39289884302008102100000) or «Door Sill Plate Replacement (Coupe)»(ref-302292-S13081590032008102100000) .
  4. Remove the rear floor air dust rear footwell (1).
  5. Remove the brace, instrument panel (I/P) padding. Remove the left brace (3) when replacing the left air duct for footwell. Remove the 4 bolts. Remove the right brace when replacing the right (2) air duct for footwell. Remove the 2 bolts.
  6. Detach and lift the floor covering at front in area or rear air duct for footwell.
  7. Remove the air duct rear footwell (1). Remove the air duct and withdraw to the front.
  1. Install the air duct footwell rear.
  2. Position and attach floor covering at front in area or rear air duct for footwell.
  3. Install brace, instrument panel padding.
  4. Install the left brace when replacing the left air duct for footwell. Tighten: Tighten the 4 bolts to 13 N.m (113 lb in).
  5. Install the right brace when replacing the right air duct for footwell. Tighten: Tighten the 2 bolts to 13 N.m (113 lb in).
  6. Install the air distribution rear footwell.
  7. Insert the air distribution footwell at top and at the bottom slide onto the air duct footwell rear.
  8. Install the door sill plate. Refer to «Door Sill Plate Replacement (Sedan)»(ref-302292-S39289884302008102100000) or «Door Sill Plate Replacement (Coupe)»(ref-302292-S13081590032008102100000) .
  9. Install the front floor console. Refer to «Front Floor Console Replacement»(ref-302290-S10871999652008102100000) .
  10. Install the front seat. Refer to «Front Seat Replacement - Bucket»(ref-302356-S37792874442008102100000) .
  1. Drain the coolant. Collect the coolant in a drip pan.
  2. Remove the blower module drain hose (1). Remove the 2 bolts.
  3. Disconnect the 2 coolant hoses. Release the 2 quick-release fittings.
  4. For vehicles equipped with the heater housing insulator, remove the air inlet screen (1).
  5. For vehicles equipped with the heater housing insulator, remove the windshield wiper arms (2).
  6. Remove the 2 covers. Remove the 2 nuts.
  7. Remove the 2 washers.
  8. Remove the 2 wiper arms from the shaft.
  9. For vehicles equipped with the heater housing insulator, remove the air inlet screen (1). Lift the air inlet screen in the dash area. Release the 5 clips (3). Remove the hose (2) for the windshield washer system.
  10. For vehicles equipped with the heater housing insulator, detach the air duct housing from the dash outside. Remove the 8 bolts.
  11. Remove the front floor console. Refer to «Front Floor Console Replacement»(ref-302290-S10871999652008102100000) .
  12. For vehicles equipped with air conditioning (A/C), remove the air duct rear footwell (1).
  13. Remove the front floor console bracket right.
  14. Detach and remove the heater core cover. Remove the 8 bolts (1, 2).
  15. For vehicles equipped with the heater housing insulator, remove the insulator.
  16. Remove the heater core with heater pipes.
  17. Detach the heater pipes. Detach the 2 heater pipes.
  1. Install the heater pipes to the heater core. Replace the 2 sealing rings.
  2. Insert the heater core.
  3. For vehicles equipped with an insulator, install the insulator.
  4. Install the heater core cover. Tighten: Tighten the 8 bolts to 6 N.m (53 lb in).
  5. Install the right center console bracket. Tighten: Tighten the 2 bolts to 13 N.m (113 lb in).
  6. Install the air duct rear footwell.
  7. Install the front floor console. Refer to «Front Floor Console Replacement»(ref-302290-S10871999652008102100000) .
  8. For vehicles equipped with an insulator, attach the air duct housing to the dash outside. Tighten: Tighten the 8 bolts to 6 N.m (53 lb in).
  9. For vehicles equipped with an insulator, fit the air inlet screen. Attach the screen washer hose. Clip in the 5 clips.
  10. For vehicles equipped with an insulator, install the windshield wiper arms. Install the 2 wiper arms to the shaft. Install the 2 washers. Tighten: Tighten the 2 nuts to 17 N.m (13 lb ft). Install the 2 cover caps.
  11. For vehicles equipped with an insulator, install the air inlet screen.
  12. Install the coolant hoses to heater core. Slide the 2 locks on the quick-release fittings in the arrow direction up to the stop. Plastic rings (green) are covered. Install the 2 quick-release fittings on the heater core (1) connections up to the stop. Note the markings applied. Slide the 2 locks (3) on the quick-release fittings in the arrow direction up to the stop. Plastic rings (green) must be visible. Inspect the correct seat of quick-release fittings and visibility of the plastic rings (arrows).
  13. Install the drain hose. Tighten: Tighten the 2 bolts to 5 N.m (44 lb in).
  14. Fill and bleed the cooling system. Refer to «Cooling System Draining and Filling»(ref-302344-S34056996812008102100000) .
  15. Inspect the coolant system for leaks. Refer to «Cooling System Leak Testing»(ref-302344-S10139799192008102100000) .

More articles — Heating, Ventilation, and Air Conditioning