Home ReviewsRefund
Home/Saturn/Aura/Saturn Aura I (2006-2010)/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 Aura I

Automatic HVAC System 27 illustrations ~3754 words

Removal Procedure

  1. Remove the drive belt from the A/C compressor. Refer to «Drive Belt Replacement»(ref-301512-S17898609722008101700000) for the 2.4L engine or «Drive Belt Replacement»(ref-301513-S36274356542008101700000) for the 3.5L engine or «Drive Belt Replacement»(ref-301505-S42749017972008101700000) for the 3.6L engine.
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
  3. Remove the lower air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-301507-S41457736352008101700000) .
  4. Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools»(ref-301492-S29180992532008101700000) .
  5. Remove the compressor clutch plate from the compressor.
  6. Remove the compressor pulley snap ring using the J 6083 . See «Special Tools»(ref-301492-S29180992532008101700000) .
  7. Remove the compressor pulley from the compressor.
  8. Remove the compressor clutch coil snap ring using the J 6083 . See «Special Tools»(ref-301492-S29180992532008101700000) .
  9. Remove the compressor clutch coil from the compressor.

Installation Procedure

  1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air.
  2. Install the compressor clutch coil to the compressor.
  3. Install the compressor clutch coil snap ring using the J 6083 . See «Special Tools»(ref-301492-S29180992532008101700000) .
  4. Install the compressor pulley to the compressor.
  5. Install the compressor pulley snap ring using the J 6083 . See «Special Tools»(ref-301492-S29180992532008101700000) .
  6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate.
  7. Install the compressor clutch plate to the compressor.
  8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap.
  9. Install the clutch drive plate bolt.
  10. Tighten the compressor clutch drive plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools»(ref-301492-S29180992532008101700000) . Tighten: Tighten the bolt to 12 N.m (106 lb in).
  11. Install the lower air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-301507-S41457736352008101700000) .
  12. Lower the vehicle.
  13. Install the drive belt to the A/C compressor. Refer to «Drive Belt Replacement»(ref-301512-S17898609722008101700000) for the 2.4L engine or «Drive Belt Replacement»(ref-301513-S36274356542008101700000) for the 3.5L engine or «Drive Belt Replacement»(ref-301505-S42749017972008101700000) for the 3.6L engine.
  14. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-301492-S29180992532008101700000) .

Scheme 11

Scheme 11: Compressor Pressure Relief Valve Replacement (LY7)
Scheme 11: Compressor Pressure Relief Valve Replacement (LY7)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the A/C compressor. Refer to Compressor Replacement (LY7) or Compressor Replacement (LAT) or Compressor Replacement (LE5) or Compressor Replacement (LZ4) .
1Compressor Pressure Relief Valve Tighten: 8 N.m (70 lb in)

Scheme 12

Scheme 12: Compressor Pressure Relief Valve Replacement (LAT, LE5)
Scheme 12: Compressor Pressure Relief Valve Replacement (LAT, LE5)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Raise and support vehicle. Refer to Lifting and Jacking the Vehicle .
1Compressor Pressure Relief Valve NOTE: Refer to Fastener Notice . Tip: Leak test the fittings of the components using J 39400-A . See Special Tools . Tighten: 8 N.m (70 lb in)
NOTE
Refer to Fastener Notice .

Scheme 13

Scheme 13: Compressor Pressure Relief Valve Replacement (LZ4)
Scheme 13: Compressor Pressure Relief Valve Replacement (LZ4)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the A/C compressor. Refer to Compressor Replacement (LY7) or Compressor Replacement (LAT) or Compressor Replacement (LE5) or Compressor Replacement (LZ4) .
1Compressor Pressure Relief Valve NOTE: Refer to Fastener Notice . Tighten: 8 N.m (70 lb in)
NOTE
Refer to Fastener Notice .
  1. Remove the seal washer from the A/C refrigerant component.
  2. Inspect the seal 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 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.
  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.
  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.

Scheme 14

Scheme 14: Air Conditioning Compressor and Condenser Hose Replacement (LY7)
Scheme 14: Air Conditioning Compressor and Condenser Hose Replacement (LY7)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner intake duct from the air cleaner assembly. Refer to Air Cleaner Inlet Duct Replacement . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front fender liner. Refer to Front Fender Liner Replacement .
1A/C Compressor and Condenser Connector Tip: Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs. Remove the A/C compressor hose from the evaporator hose assembly and discard O-rings. Refer to O-Ring Replacement .
2A/C Compressor Hose Clip Bracket Bolt NOTE: Refer to Fastener Notice . Tighten: 10 N.m (89 lb in)
3A/C Compressor Hose Nut Tip: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten: 20 N.m (15 lb ft)
4Sealing Washer Tip: Remove and discard sealing washers. Refer to Sealing Washer Replacement .
5A/C Compressor Hose Bolt Tighten: 20 N.m (15 lb ft)
6Sealing Washer Tip: Remove and discard sealing washers. Refer to Sealing Washer Replacement .
7A/C Compressor Hose Assembly Tip: Note routing of the A/C compressor hose to ensure proper routing. Using J 39400 leak test A/C compressor hose connections. See Special Tools .
NOTE
Refer to Fastener Notice .

Scheme 15

Scheme 15: Air Conditioning Compressor and Condenser Hose Replacement (LE5)
Scheme 15: Air Conditioning Compressor and Condenser Hose Replacement (LE5)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner intake duct fro the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1st Design) or Air Cleaner Assembly Replacement (2nd Design) . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front fender liner. Refer to Front Fender Liner Replacement .
1A/C Compressor and Condenser Connector Procedure Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs. Remove the A/C compressor hose from the evaporator hose assembly and discard O-rings. Refer to O-Ring Replacement .
2A/C Compressor Hose Nut NOTE: Refer to Fastener Notice . Tip: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten: 20 N.m (15 lb ft)
3Sealing Washer Tip: Remove and discard sealing washers. Refer to Sealing Washer Replacement .
4A/C Compressor Hose Bolt Tighten: 20 N.m (15 lb ft)
5Sealing Washer Tip: Remove and discard sealing washers. Refer to Sealing Washer Replacement .
6A/C Compressor Hose Assembly Tip: Note routing of the A/C compressor hose to ensure proper routing. Using J 39400 leak test A/C compressor hose connections. See Special Tools . Special Tools: J 39400 Electronic Halogen Leak Detector. See Special Tools .
NOTE
Refer to Fastener Notice .

Scheme 16

Scheme 16: Air Conditioning Compressor and Condenser Hose Replacement (LZ4)
Scheme 16: Air Conditioning Compressor and Condenser Hose Replacement (LZ4)
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner intake duct from the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1st Design) or Air Cleaner Assembly Replacement (2nd Design) . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front fender liner. Refer to Front Fender Liner Replacement .
1Connector, A/C Compressor and Condenser Procedure Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs. Remove the A/C compressor hose from the evaporator hose assembly and discard O-rings. Refer to O-Ring Replacement .
2Nut, A/C Compressor Hose Tip: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten: 20 N.m (15 lb ft)
3Washer, Sealing Tip: Remove and discard sealing washers. Refer to Sealing Washer Replacement .
4Bolt, A/C Compressor Hose Tighten: 20 N.m (15 lb ft)
5Washer, Sealing Tip: Remove and discard sealing washers. Refer to Sealing Washer Replacement .
6Hose Assembly, A/C Compressor Procedure Note routing of the A/C compressor hose to ensure proper routing. Using J 39400 leak test A/C compressor hose connections. See Special Tools .
NOTE
Refer to Fastener Notice .

Scheme 17

Scheme 17: Air Conditioning Compressor and Condenser Hose Replacement (LAT)
Scheme 17: Air Conditioning Compressor and Condenser Hose Replacement (LAT)
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner intake duct fro the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1st Design) or Air Cleaner Assembly Replacement (2nd Design) . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front fender liner. Refer to Front Fender Liner Replacement .
1Connector, A/C Compressor and Condenser Procedure Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs. Remove the A/C compressor hose from the evaporator hose assembly and discard O-rings. Refer to O-Ring Replacement .
2Nut, A/C Compressor Hose Tip: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten: 20 N.m (15 lb ft)
3Washer, Sealing Tip: Remove and discard sealing washers. Refer to Sealing Washer Replacement .
4Bolt, A/C Compressor Hose Tighten: 20 N.m (15 lb ft)
5Washer, Sealing Tip: Remove and discard sealing washers. Refer to Sealing Washer Replacement .
6Hose Assembly, A/C Compressor Procedure Note routing of the A/C compressor hose to ensure proper routing. Using J 39400 leak test A/C compressor hose connections. See Special Tools .
NOTE
Refer to Fastener Notice .
  1. Uncap A/C components.
  2. Install new sealing washers. Refer to «Sealing Washer Replacement»(ref-301492-S34906372642008101700000) .
  3. Install the suction hose.
  4. Install the liquid line bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  5. Install the refrigerant pressure sensor wire harness connector.
  6. Install the line clip to the dash.
  7. Install the suction hose to the dash clip.
  8. Install the suction hose and liquid line to the TXV.
  9. Install the suction hose and liquid line nut to the TXV. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  10. Install new O-rings. Refer to «O-Ring Replacement»(ref-301492-S34628561182008101700000) .
  11. Install the suction hose to the compressor hose.
  12. Install the compressor hose and liquid line connector.
  13. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-301492-S16453614042008101700000) .
  14. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-301492-S29180992532008101700000) .
  15. Install the surge tank to the surge tank bracket.

Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement

CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner intake duct from the air cleaner assembly. Refer to Air Cleaner Inlet Duct Replacement . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front fender liner. Refer to Front Fender Liner Replacement .
1A/C Compressor and Condenser Connector Tip: Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs. Remove the A/C compressor hose from the evaporator hose assembly and discard O-rings. Refer to O-Ring Replacement .
2A/C Compressor Hose Clip Bracket Bolt NOTE: Refer to Fastener Notice . Tighten: 10 N.m (89 lb in)
3A/C Compressor Hose Nut Tip: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten: 20 N.m (15 lb ft)
4Sealing Washer Tip: Remove and discard sealing washers. Refer to Sealing Washer Replacement .
5A/C Compressor Hose Bolt Tighten: 20 N.m (15 lb ft)
6Sealing Washer Tip: Remove and discard sealing washers. Refer to Sealing Washer Replacement .
7A/C Compressor Hose Assembly Tip: Note routing of the A/C compressor hose to ensure proper routing. Using J 39400 leak test A/C compressor hose connections. See Special Tools .
NOTE
Refer to Fastener Notice .
  1. Uncap A/C components.
  2. Install new sealing washers. Refer to «Sealing Washer Replacement»(ref-301492-S34906372642008101700000) .
  3. Install the liquid line.
  4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
  5. Install the liquid line and compressor hose to the condenser.
  6. Install the liquid line and compressor hose bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  7. Install the liquid line to the rail clip.
  8. Install the right radiator air deflector.
  9. Install the right radiator air deflector retainers.
  10. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(ref-301500-S02566820132008101700000) .
  11. Lower the vehicle.
  12. Install the suction hose and liquid line to the TXV.
  13. Install the suction hose and liquid line nut to the TXV. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  14. Install the liquid line to the dash clip.
  15. Install the suction hose to the dash clip.
  16. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-301532-S34449277472008101700000) .
  17. Install the liquid line bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  18. Install the refrigerant pressure sensor. Tighten: Tighten the bolt to 5 N.m (44 lb in).
  19. Install the refrigerant pressure sensor wire harness connector.
  20. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-301492-S16453614042008101700000) .
  21. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-301492-S29180992532008101700000) .
  22. Install the surge tank to the surge tank bracket.

Scheme 18

Scheme 18: Air Conditioning Evaporator Thermal Expansion Valve Hose Replacement
Scheme 18: Air Conditioning Evaporator Thermal Expansion Valve Hose Replacement
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1st Design) or Air Cleaner Assembly Replacement (2nd Design) .
1A/C Evaporator TXV Hose Nut NOTE: Refer to Fastener Notice . Tighten: 10 N.m (89 lb in) Tip: Remove the A/C Evaporator TXV Hose from the evaporator hose assembly and discard O-rings. Refer to O-Ring Replacement .
2Release hose/pipe from attaching clips
3A/C Evaporator TXV Hose Tip: Cap all hose/pipe fittings.
NOTE
Refer to Fastener Notice .
  1. Uncap A/C components.
  2. Install new sealing washers. Refer to «Sealing Washer Replacement»(ref-301492-S34906372642008101700000) .
  3. Install the refrigerant filter into the line.
  4. Install the line clip to the dash.
  5. Install the suction hose and liquid line to the TXV.
  6. Install the suction hose and liquid line nut to the TXV. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  7. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-301492-S16453614042008101700000) .
  8. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-301492-S29180992532008101700000) .
  9. Install the surge tank to the surge tank bracket.

Scheme 19

Scheme 19: Suction Screen Replacement
Scheme 19: Suction Screen Replacement
CalloutComponent Name
Preliminary Procedure: Remove the A/C compressor. Refer to Compressor Replacement (LY7) or Compressor Replacement (LAT) or Compressor Replacement (LE5) or Compressor Replacement (LZ4) .
1Suction Screen Tip: Remove the suction screen from the A/C compressor suction port using a flat bladed tool or pick.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-301492-S16453614042008101700000) .
  2. Remove the service port valve core using J 46246 or equivalent. See «Special Tools»(ref-301492-S29180992532008101700000) .
  1. Install the service port valve core using J 46246 or equivalent. See «Special Tools»(ref-301492-S29180992532008101700000) . 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-301492-S16453614042008101700000) .
  3. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-301492-S29180992532008101700000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-301492-S16453614042008101700000) .
  2. Remove the surge tank from the surge tank bracket.
  3. Remove the suction line from the dash clip.
  4. Remove the liquid line from the dash clip.
  5. Remove the liquid line and suction line nut from the thermal expansion valve (TXV).
  6. Remove the suction line from the TXV.
  7. Remove the liquid line from the TXV.
  8. Remove the TXV screws.
  9. Remove the TXV.
  10. Remove and discard the sealing washers.
  1. Uncap A/C components.
  2. Install new sealing washers. Refer to «Sealing Washer Replacement»(ref-301492-S34906372642008101700000) .
  3. Install the TXV.
  4. Install the TXV screws. Tighten: Tighten the TXV screws to 7 N.m (62 lb in).
  5. Install the liquid line to the TXV.
  6. Install the suction line to the TXV.
  7. Install the liquid line and suction line nut to the TXV. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  8. Install the liquid line to the dash clip.
  9. Install the suction line to the dash clip.
  10. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-301492-S16453614042008101700000) .
  11. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-301492-S29180992532008101700000) .
  12. Install the surge tank to the surge tank bracket.
  1. Remove the refrigerant pressure sensor wire harness connector.
  2. Remove the refrigerant pressure sensor.
  3. Remove and discard the O-ring.
  1. Install a new O-ring. Refer to «O-Ring Replacement»(ref-301492-S34628561182008101700000) .
  2. Install the refrigerant pressure sensor. Tighten: Tighten to 5 N.m (44 lb in).
  3. Install the refrigerant pressure sensor wire harness connector.
  4. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-301492-S29180992532008101700000) .
  1. Uncap A/C components.
  2. Install new sealing washers. Refer to «Sealing Washer Replacement»(ref-301492-S34906372642008101700000) .
  3. Install the upper seal.
  4. If replacing the condenser, add the specific amount of PAG® oil directly to the condenser. Refer to «Refrigerant System Capacities»(ref-301492-S42102639822008101700000) .
  5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
  6. Insert condenser mounting tabs into the radiator clips.
  7. Install the condenser mounting nuts.
  8. Install the condenser mounting bolts. Tighten: Tighten the mounting bolts to 6 N.m (53 lb in).
  9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
  10. The radiator air side seals must be in the proper position for proper airflow.
  11. Install both lower radiator mounting brackets.
  12. Install both lower radiator mounting brackets bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
  13. Install the liquid line to the condenser.
  14. Install the compressor hose to the condenser.
  15. Install the liquid line and compressor hose bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  16. Install the left radiator air deflector.
  17. Install the left radiator air deflector retainers.
  18. Install the right radiator air deflector.
  19. Install the right radiator air deflector retainers.
  20. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(ref-301500-S02566820132008101700000) .
  21. Install the lower radiator air deflector.
  22. Install the lower radiator air deflector retainers.
  23. Lower the vehicle.
  24. Remove the rope attached to the radiator and upper tie bar.
  25. Install both upper radiator support brackets.
  26. Install both upper radiator support bracket bolts. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  27. Install the left and right headlamp assembly. Refer to «Headlamp Replacement»(ref-301486-S33623984482008101700000) .
  28. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-301492-S16453614042008101700000) .
  29. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-301492-S29180992532008101700000) .
  1. Remove the air conditioner (A/C) lines from the thermal expansion valve. Refer to «Thermal Expansion Valve Replacement»(ref-301492-S37651410962008101700000) .
  2. Remove the heater hose from the heater core. Refer to «Heater Inlet Hose Replacement (LY7)»(ref-301492-S06400805932008101700000) or «Heater Inlet Hose Replacement (LZ4)»(ref-301492-S05728691422008101700000) or «Heater Inlet Hose Replacement (LAT Pump to Engine)»(ref-301492-S25343195542008101700000) or «Heater Inlet Hose Replacement (LAT Pump to Heater Core)»(ref-301492-S16696580542008101700000) or «Heater Inlet Hose Replacement (LE5)»(ref-301492-S28006238052008101700000) and «Heater Outlet Hose Replacement (LY7)»(ref-301492-S32270785542008101700000) or «Heater Outlet Hose Replacement (LAT)»(ref-301492-S29003434502008101700000) or «Heater Outlet Hose Replacement (LE5)»(ref-301492-S14059034792008101700000) .
  3. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Reinforcement Replacement»(ref-301482-S25575497772008101700000) .
  4. Remove the recirculation actuator wire harness connector.
  5. Remove the air temperature actuator wire harness connector.
  6. Remove the mode actuator wire harness connector.
  7. Remove the blower motor wire harness connector.
  8. Remove the blower motor resistor wire harness connector.
  9. Remove the left hand side window defogger outlet duct.
  10. Remove the HVAC module assembly mounting bolts from the instrument panel reinforcement.
  11. Remove the HVAC module assembly to dash panel bolts (1).
  12. Remove the HVAC module assembly (1).

Scheme 20

Scheme 20: Installation Procedure
Scheme 20: Installation Procedure
  1. Install the HVAC module assembly (1).
  2. Install the HVAC module assembly to dash panel bolts (1). Tighten: Tighten the bolts to 10 N.m (88 lb in).
  3. Install the HVAC module assembly mounting bolts to the instrument panel reinforcement. Tighten: Tighten the bolts to 5 N.m (44 lb in).
  4. Install the left hand side window defogger outlet duct.
  5. Install the blower motor resistor wire harness connector.
  6. Install the blower motor wire harness connector.
  7. Install the mode actuator wire harness connector.
  8. Install the air temperature actuator wire harness connector.
  9. Install the recirculation actuator wire harness connector.
  10. Install the I/P assembly. Refer to «Instrument Panel Reinforcement Replacement»(ref-301482-S25575497772008101700000) .
  11. Install the heater hoses to the heater core. Refer to «Heater Inlet Hose Replacement (LY7)»(ref-301492-S06400805932008101700000) or «Heater Inlet Hose Replacement (LZ4)»(ref-301492-S05728691422008101700000) or «Heater Inlet Hose Replacement (LAT Pump to Engine)»(ref-301492-S25343195542008101700000) or «Heater Inlet Hose Replacement (LAT Pump to Heater Core)»(ref-301492-S16696580542008101700000) or «Heater Inlet Hose Replacement (LE5)»(ref-301492-S28006238052008101700000) and «Heater Outlet Hose Replacement (LY7)»(ref-301492-S32270785542008101700000) or «Heater Outlet Hose Replacement (LAT)»(ref-301492-S29003434502008101700000) or «Heater Outlet Hose Replacement (LE5)»(ref-301492-S14059034792008101700000) .
  12. Install the A/C lines to the thermal expansion valve. Refer to «Thermal Expansion Valve Replacement»(ref-301492-S37651410962008101700000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-301492-S31213060832008101700000) .
  2. Remove the center floor air outlet duct screws.
  3. Remove the center floor air outlet duct.
  4. Drill out the lower HVAC module case heat stakes.
  5. Remove the lower HVAC module case screws.
  6. Remove the lower HVAC module case.
  7. Remove the thermal expansion valve screws.
  8. Remove the thermal expansion valve.
  9. Remove and discard the sealing washers.
  10. Remove the evaporator.
  1. If replacing the evaporator, add the specific amount of PAG® oil directly to the evaporator. Refer to «Refrigerant System Capacities»(ref-301492-S42102639822008101700000) .
  2. Install the evaporator.
  3. Install new sealing washers. Refer to «Sealing Washer Replacement»(ref-301492-S34906372642008101700000) .
  4. Install the thermal expansion valve.
  5. Install the thermal expansion valve screws. Tighten: Tighten the screws to 7 N.m (62 lb in).
  6. Install the lower HVAC module case.
  7. Install the lower HVAC module case screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  8. Install the center floor air outlet duct.
  9. Install the center floor air outlet duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  10. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-301492-S31213060832008101700000) .

Scheme 21

Scheme 21: Heater Inlet Hose Replacement (LY7)
Scheme 21: Heater Inlet Hose Replacement (LY7)
CalloutComponent Name
Preliminary Procedure: Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Heater Inlet Hose Assembly Tip: Using J 38185 to reposition of the heater inlet hose clamps. Remove the heater inlet hose from the heater core and engine. Special Tools: J 38185 Hose Clamp Pliers

Scheme 22

Scheme 22: Heater Inlet Hose Replacement (LZ4)
Scheme 22: Heater Inlet Hose Replacement (LZ4)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement .
1Heater Inlet Hose Assembly Tip: Using J 38185 to reposition of the heater inlet hose clamps. Remove the heater inlet hose from the heater core and engine. Special Tools: J 38185 Hose Clamp Pliers

Scheme 23

Scheme 23: Heater Inlet Hose Replacement (LAT Pump to Engine)
Scheme 23: Heater Inlet Hose Replacement (LAT Pump to Engine)
CalloutComponent Name
Preliminary Procedures: Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Heater Inlet Hose Clamp (Qty: 2)
2Heater Inlet Hose

Scheme 24

Scheme 24: Heater Inlet Hose Replacement (LAT Pump to Heater Core)
Scheme 24: Heater Inlet Hose Replacement (LAT Pump to Heater Core)
CalloutComponent Name
Preliminary Procedures: Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Heater Inlet Hose Clamp (Qty: 2)
2Heater Inlet Hose
  1. Partially drain the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Remove the surge tank from the surge tank bracket.
  3. Reposition the heater inlet hose clamp at the heater core using the J 38185 .
  4. Remove the heater inlet hose from the heater core.
  5. Reposition the heater inlet hose clamp at the engine using the J 38185 .
  6. Remove the heater inlet hose from the engine.
  1. Install the heater inlet hose to the engine.
  2. Reposition the heater inlet hose clamp at the engine using the J 38185 .
  3. Install the heater inlet hose to the heater core.
  4. Reposition the heater inlet hose clamp at the heater core using the J 38185 .
  5. Install the surge tank to the surge tank bracket.
  6. Fill the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .

Scheme 25

Scheme 25: Heater Outlet Hose Replacement (LY7)
Scheme 25: Heater Outlet Hose Replacement (LY7)
CalloutComponent Name
Preliminary Procedure: Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Heater Outlet Hose Assembly Tip: Using J 38185 to reposition of the heater outlet hose clamps. Remove the heater outlet hose from the heater core and engine. Special Tools: J 38185 Hose Clamp Pliers

Scheme 26

Scheme 26: Heater Outlet Hose Replacement (LAT)
Scheme 26: Heater Outlet Hose Replacement (LAT)
CalloutComponent Name
Preliminary Procedures: Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Heater Outlet Hose Clamp (Qty: 2)
2Heater Outlet Hose
  1. Partially drain the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Remove the surge tank from the surge tank bracket.
  3. Reposition the heater outlet hose clamp at the heater core using the J 38185 .
  4. Remove the heater outlet hose from the heater core.
  5. Reposition the heater outlet hose clamp at the engine using the J 38185 .
  6. Remove the heater outlet hose from the engine.
  1. Install the heater outlet hose to the engine.
  2. Reposition the heater outlet hose clamp at the engine using the J 38185 .
  3. Install the heater outlet hose to the heater core.
  4. Reposition the heater outlet hose clamp at the heater core using the J 38185 .
  5. Install the surge tank to the surge tank bracket.
  6. Fill the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .

Scheme 27

Scheme 27: Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement
Scheme 27: Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the heater inlet hose from the heater pipe assembly. Refer to Heater Inlet Hose Replacement (LY7) or Heater Inlet Hose Replacement (LZ4) or Heater Inlet Hose Replacement (LAT Pump to Engine) or Heater Inlet Hose Replacement (LAT Pump to Heater Core) or Heater Inlet Hose Replacement (LE5) . Remove the heater outlet hose from the heater pipe assembly. Refer to Heater Outlet Hose Replacement (LY7) or Heater Outlet Hose Replacement (LAT) or Heater Outlet Hose Replacement (LE5) . Remove the air cleaner duct. Refer to Air Cleaner Outlet Duct Replacement .
1Pipe Assembly - Heater Inlet and Outlet Pipe - Left - Nut NOTE: Refer to Fastener Notice . Tighten: 10 N.m (89 lb in)
2Heater Inlet and Outlet Pipe - Left Pipe Assembly Tip: Using J 38185 , disconnect the left heater pipe assembly from the front heater pipe assembly.
3Pipe Assembly - Heater Inlet and Outlet Pipe - Front - Bolt Tighten: 25 N.m (18 lb in)
4Pipe Assembly - Heater Inlet and Outlet Pipe - Front - Stud Tighten: 10 N.m (89 lb in)
5Heater Inlet and Outlet Pipe - Front Pipe Assembly
NOTE
Refer to Fastener Notice .

Scheme 28

Scheme 28: Heater Outlet Hose Replacement - Connector to Engine (LZ4)
Scheme 28: Heater Outlet Hose Replacement - Connector to Engine (LZ4)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the air cleaner outlet duct. Refer to Air Cleaner Inlet Duct Replacement . Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement .
1Heater Outlet Hose Tip: Using SA9111E to reposition of the heater outlet hose clamps. Remove the heater outlet hose from the connector and the engine.

Scheme 29

Scheme 29: Heater Outlet Hose Replacement - Heater Core to Connector (LZ4)
Scheme 29: Heater Outlet Hose Replacement - Heater Core to Connector (LZ4)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the air cleaner outlet duct. Refer to Air Cleaner Inlet Duct Replacement . Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement .
1Heater Outlet Hose Tip: Using SA9111E to reposition of the heater outlet hose clamps. Remove the heater outlet hose from the connector and the heater core.

Scheme 30

Scheme 30: Heater Coolant Pump Replacement (LAT)
Scheme 30: Heater Coolant Pump Replacement (LAT)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the inlet and outlet hose clamp from the auxiliary heater pump. Remove the inlet and outlet hoses from the auxiliary heater pump.
1Auxiliary Heater Coolant Pump Screw NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Auxiliary Heater Coolant Pump Tip: Disconnect electrical connection.
NOTE
Refer to Fastener Notice .

Scheme 31

Scheme 31: Blower Motor Resistor Replacement
Scheme 31: Blower Motor Resistor Replacement
CalloutComponent Name
Preliminary Procedures Remove the right close out panel. Refer to Instrument Panel Insulator Panel Replacement - Right Side . Disconnect the blower motor resistor electrical connector.
1Blower Motor Resistor Screw (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2Blower Motor Resistor
NOTE
Refer to Fastener Notice .
  1. Remove the right closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(ref-301482-S17342379292008101700000) .
  2. Remove the blower motor wire harness connector.
  3. Cut out the blower motor using a utility knife in the narrow groove of the lower case.
  4. Remove the blower motor.
  5. Remove the blower motor nuts.
  6. Remove the blower motor from the blower motor cup.
  1. Install the new blower motor to the blower motor cup.
  2. Install the blower motor nuts. Tighten: Tighten the nuts to 2.4 N.m (21 lb in).
  3. Install the motor blower seal to the blower motor service ring.
  4. Install the blower motor.
  5. Install the blower motor attachment ring.
  6. Install the blower motor screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  7. Install the blower motor wire harness connector.
  8. Install the right closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(ref-301482-S17342379292008101700000) .

Scheme 32

Scheme 32: Side Window Air Outlet Replacement
Scheme 32: Side Window Air Outlet Replacement
CalloutComponent Name
1Instrument Panel Assembly Refer to Instrument Panel Assembly Replacement .
2Left Side Window Air Outlet Assembly Screw (Qty: 1) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
3Right Side Window Air Outlet Assembly Screw (Qty: 1) Tighten: 2 N.m (18 lb in)
4Left Side Window Air Outlet Assembly
5Right Side Window Air Outlet Assembly
NOTE
Refer to Fastener Notice .

Scheme 33

Scheme 33: Instrument Panel Outer Air Outlet Replacement - Left Side
Scheme 33: Instrument Panel Outer Air Outlet Replacement - Left Side
CalloutComponent Name
1Knee Bolster Assembly Refer to Knee Bolster Replacement
2Instrument Panel Air Outlet Assembly - Left
3Retainer Clips (Qty: 2)

Scheme 34

Scheme 34: Instrument Panel Center Air Outlet Replacement
Scheme 34: Instrument Panel Center Air Outlet Replacement
CalloutComponent Name
Preliminary Procedure: Remove the instrument panel center molding. Refer to Instrument Panel Center Molding Replacement .
1Instrument Panel Center Air Outlet Assembly Tip: Use a flat-bladed plastic trim tool to release the center air outlet assembly from the instrument panel. Disconnect the electrical connections. If replacing the center air outlet, transfer all necessary components.
2Retainer Clips (Qty: 4)

Scheme 35

Scheme 35: Instrument Panel Outer Air Outlet Replacement - Right Side
Scheme 35: Instrument Panel Outer Air Outlet Replacement - Right Side
CalloutComponent Name
1Instrument Panel Compartment Assembly Refer to Instrument Panel Compartment Replacement .
2Instrument Panel Air Outlet Screw (Qty: 1) NOTE: Refer to Fastener Notice . Tighten: 2 N.m (18 lb in)
3Instrument Panel Air Outlet Assembly - Right
NOTE
Refer to Fastener Notice .
  1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(ref-301482-S20108830612008101700000) .
  2. Disconnect the wire harness clip at the left air outlet duct.
  3. Remove the left air outlet duct screws.
  4. Remove the left air outlet duct.
  1. Install the left air outlet duct.
  2. Install the left air outlet duct screws. Tighten: Tighten the left air outlet duct screws to 2.5 N.m (22 lb in).
  3. Connect the wire harness clip at the left air outlet duct.
  4. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(ref-301482-S20108830612008101700000) .

Scheme 36

Scheme 36: Removal Procedure
Scheme 36: Removal Procedure
  1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(ref-301482-S20108830612008101700000) .
  2. Remove the right hand side window defogger duct screws.
  3. Remove the right hand side window defogger duct.
  4. Disconnect the wire harness clip at the right air outlet duct.
  5. Remove the right air outlet duct screws.
  6. Remove the right air outlet duct.
  1. Install the right air outlet duct.
  2. Install the right air outlet duct screws. Tighten: Tighten the right air outlet duct screws to 2.5 N.m (22 lb in).
  3. Connect the wire harness clip at the right air outlet duct.
  4. Install the right hand side window defogger duct.
  5. Install the right hand side window defogger duct screws. Tighten: Tighten the screws to 2.5 N.m (22 lb in).
  6. Install the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(ref-301482-S20108830612008101700000) .

Scheme 37

Scheme 37: Center Air Outlet Duct Replacement
Scheme 37: Center Air Outlet Duct Replacement
CalloutComponent Name
Preliminary Procedures Remove the center air outlet. Refer to Instrument Panel Center Air Outlet Replacement . Disconnect the upper air temperature sensor electrical connector.
1Air Temperature Sensor - Upper
2Air Distribution Duct - Center
  1. Remove the instrument panel (I/P) pad. Refer to «Instrument Panel Upper Trim Panel Replacement»(ref-301482-S07595624762008101700000) .
  2. Press on the 2 tabs of the windshield defroster duct.
  3. Remove the windshield defroster duct.
  1. Install the windshield defroster duct.
  2. Install the I/P pad. Refer to «Instrument Panel Upper Trim Panel Replacement»(ref-301482-S07595624762008101700000) .
  1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(ref-301482-S20108830612008101700000) .
  2. Remove the left hand side window defogger duct screws.
  3. Remove the left hand side window defogger duct.
  1. Install the left hand side window defogger duct.
  2. Install the left hand side window defogger duct screws. Tighten: Tighten the screws to 2.5 N.m (22 lb in).
  3. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(ref-301482-S20108830612008101700000) .
  1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(ref-301482-S20108830612008101700000) .
  2. Remove the right hand side window defogger duct screws.
  3. Remove the right hand side window defogger duct.
  1. Install the right hand side window defogger duct.
  2. Install the right hand side window defogger duct screws. Tighten: Tighten the screws to 2.5 N.m (22 lb in).
  3. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(ref-301482-S20108830612008101700000) .
  1. Remove the console. Refer to «Console Replacement»(ref-301482-S26582959672008101700000) .
  2. Remove the center floor air duct screws.
  3. Remove the center floor air duct.
  1. Install the center floor air duct.
  2. Install the center floor air duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  3. Install the console. Refer to «Console Replacement»(ref-301482-S26582959672008101700000) .
  1. Remove the console. Refer to «Console Replacement»(ref-301482-S26582959672008101700000) .
  2. Remove the left front seat. Refer to «Front Seat Replacement - Bucket»(ref-301481-S21815573952008101700000) .
  3. Remove the left front carpet retainer. Refer to «Front Carpet Retainer Replacement»(ref-301480-S13116351252008101700000) .
  4. Remove the left center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(ref-301484-S38878971632008101700000) .
  5. Remove the floor carpet enough to access the left rear floor duct. Refer to «Front Floor Panel Carpet Replacement»(ref-301480-S18761410762008101700000) .
  6. Remove the left rear floor duct.
  1. Install the left rear floor duct.
  2. Install the floor carpet. Refer to «Front Floor Panel Carpet Replacement»(ref-301480-S18761410762008101700000) .
  3. Install the left center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(ref-301484-S38878971632008101700000) .
  4. Install the left front carpet retainer. Refer to «Front Carpet Retainer Replacement»(ref-301480-S13116351252008101700000) .
  5. Install the left front seat. Refer to «Front Seat Replacement - Bucket»(ref-301481-S21815573952008101700000) .
  6. Install the console. Refer to «Console Replacement»(ref-301482-S26582959672008101700000) .
  1. Remove the console. Refer to «Console Replacement»(ref-301482-S26582959672008101700000) .
  2. Remove the right front seat. Refer to «Front Seat Replacement - Bucket»(ref-301481-S21815573952008101700000) .
  3. Remove the right front carpet retainer. Refer to «Front Carpet Retainer Replacement»(ref-301480-S13116351252008101700000) .
  4. Remove the right center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(ref-301484-S38878971632008101700000) .
  5. Remove the front floor carpet enough to access the right rear floor duct. Refer to «Front Floor Panel Carpet Replacement»(ref-301480-S18761410762008101700000) .
  6. Remove the right rear floor duct.
  1. Install the right rear floor duct.
  2. Install the front floor carpet. Refer to «Front Floor Panel Carpet Replacement»(ref-301480-S18761410762008101700000) .
  3. Install the right center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(ref-301484-S38878971632008101700000) .
  4. Install the right front carpet retainer. Refer to «Front Carpet Retainer Replacement»(ref-301480-S13116351252008101700000) .
  5. Install the right front seat. Refer to «Front Seat Replacement - Bucket»(ref-301481-S21815573952008101700000) .
  6. Install the console. Refer to «Console Replacement»(ref-301482-S26582959672008101700000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-301492-S31213060832008101700000) .
  2. Remove the center floor air outlet duct screws.
  3. Remove the center floor air outlet duct.
  4. Drill out the heater core cover heat stakes.
  5. Remove the heater core cover screws.
  6. Remove the heater core cover.
  1. Install the heater core cover.
  2. Install the heater core cover screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  3. Install the center floor air outlet duct.
  4. Install the center floor air outlet duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-301492-S31213060832008101700000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-301492-S31213060832008101700000) .
  2. Remove the center floor air outlet duct screws.
  3. Remove the center floor air outlet duct.
  4. Drill out the heater core cover heat stakes.
  5. Remove the heater core cover screws.
  6. Remove the heater core cover.
  7. Remove the heater core.
  1. Install the heater core.
  2. Install the heater core cover.
  3. Install the heater core cover screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  4. Install the center floor air outlet duct.
  5. Install the upper floor air outlet duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  6. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-301492-S31213060832008101700000) .

More articles — Heating, Ventilation, and Air Conditioning