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Heating, Ventilation & Air Conditioning: Removal & Installation Saturn ION I

Automatic HVAC System ~7013 words

Compressor Replacement (2.2L (L61))

Tools Required

  1. J 39400-A Halogen Leak Detector. See «Special Tools»(ref-197012-S41925114452005101000000) .
  2. J 44811 Accessory Belt Tensioner Unloader

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(ref-196958-S29238524142005101000000) in Body Front End.
  4. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
  5. Remove the drive belt.
  6. Disconnect the electrical connector from the compressor.
  7. Remove the compressor and condenser hose assembly bolt from the compressor.
  8. Remove the compressor and condenser hose assembly from the compressor.
  9. Remove and discard the sealing washers.
  10. Remove the compressor mounting bolts.
  11. Remove the compressor.

Installation Procedure

  1. If you are replacing the compressor, refer to «Compressor Oil Balancing»(ref-197012-S33117131172005101000000) .
  2. Install the compressor and the bolts to the engine. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
  3. Install new sealing washers on the hose fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  4. Install the hose assembly to the compressor.
  5. Install the assembly bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  6. Connect the compressor electrical connector.
  7. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
  8. Install the drive belt.
  9. Install the front fender liner. Refer to «Front Fender Liner Replacement»(ref-196958-S29238524142005101000000) in Body Front End.
  10. Lower the vehicle.
  11. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  12. Leak test the fittings using J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .

Compressor Replacement (2.0L (LSJ))

Tools Required

  1. J 39400-A Halogen Leak Detector. See «Special Tools»(ref-197012-S41925114452005101000000) .
  2. J 44811 Accessory Belt Tensioner Unloader
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(ref-196958-S29238524142005101000000) in Body Front End.
  4. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-196977-S11577571682005101000000) .
  5. Disconnect the electrical connector from the compressor.
  6. Remove the compressor and condenser hose assembly bolt from the compressor.
  7. Remove the compressor and condenser hose assembly from the compressor.
  8. Remove and discard the sealing washers.
  9. Remove the auxiliary intercooler pump bolts and position the pump toward the driver side of the vehicle.
  10. Remove the compressor mounting bolts.
  11. Remove the compressor.
  1. If you are replacing the compressor, refer to «Compressor Oil Balancing»(ref-197012-S33117131172005101000000) .
  2. Install the compressor and the bolts to the engine. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
  3. Install new sealing washers on the hose fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  4. Install the hose assembly to the compressor.
  5. Install the assembly bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  6. Connect the compressor electrical connector.
  7. Install the auxiliary intercooler pump. Tighten: Tighten the pump bolt to 10 N.m (88 lb in).
  8. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
  9. Install the drive belt.
  10. Install the front fender liner. Refer to «Front Fender Liner Replacement»(ref-196958-S29238524142005101000000) in Body Front End.
  11. Lower the vehicle.
  12. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  13. Leak test the fittings using J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .

Compressor Clutch Assembly Replacement

Tools Required

  1. J 37872 Universal Spanner Wrench. See «Special Tools»(ref-197012-S41925114452005101000000) .
  2. SA9149AC-8 Snap Ring Pliers. See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Remove the compressor. Refer to «Compressor Replacement (2.2L (L61))»(ref-197012-S38244308662005101000000) or «Compressor Replacement (2.0L (LSJ))»(ref-197012-S35581718972005101000000) .
  2. Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools»(ref-197012-S41925114452005101000000) .
  3. Remove the compressor clutch plate.
  4. Remove the compressor pulley snap ring using SA9149AC-8 . See «Special Tools»(ref-197012-S41925114452005101000000) .
  5. Slide the compressor pulley off of the compressor.
  6. Remove the compressor clutch coil snap ring using SA9149AC-8 . See «Special Tools»(ref-197012-S41925114452005101000000) .
  7. Slide the compressor clutch coil off of the compressor.
  1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air.
  2. Slide the compressor clutch coil onto the compressor.
  3. Install the compressor clutch coil snap ring using SA9149AC-8 . See «Special Tools»(ref-197012-S41925114452005101000000) .
  4. Slide the compressor pulley onto the compressor.
  5. Install the compressor pulley snap ring using SA9149AC-8 . See «Special Tools»(ref-197012-S41925114452005101000000) .
  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.
  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. Make certain that the new drive plate bolt has colored adhesive on at least 5 threads. Install the clutch drive plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools»(ref-197012-S41925114452005101000000) . Tighten: Tighten the compressor clutch drive plate bolt to 12 N.m (106 lb in).
  10. Install the compressor. Refer to «Compressor Replacement (2.2L (L61))»(ref-197012-S38244308662005101000000) or «Compressor Replacement (2.0L (LSJ))»(ref-197012-S35581718972005101000000) .
  11. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  12. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Remove the pressure relief valve from the compressor.
  1. Install the pressure relief valve and seal to the compressor. Tighten: Tighten the compressor pressure relief valve to 7 N.m (62 lb in).
  2. Lower the vehicle.
  3. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  4. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  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. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Disconnect the electrical connector from the pressure transducer.
  4. Remove the compressor and condenser hose assembly bolt from the compressor.
  5. Remove the compressor and condenser hose assembly from the compressor.
  6. Remove and discard the sealing washers.
  7. Remove the compressor hose from the condenser.
  8. Remove and discard the seal washer.
  9. Lower the vehicle.
  10. Remove the compressor hose from the evaporator hose.
  11. Remove and discard the seal washer.
  1. Install new sealing washers on the compressor and condenser hose fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  2. Install the A/C compressor and condenser hose assembly to the compressor.
  3. Install the A/C compressor and condenser hose assembly bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  4. Install new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  5. Install the compressor hose and nut to the evaporator hose. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  6. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  7. Install new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  8. Install the compressor hose and bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  9. Connect the pressure transducer electrical connector.
  10. Lower the vehicle.
  11. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  12. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Remove the compressor hose from the evaporator hose.
  3. Remove and discard the seal washer.
  4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  5. Remove the lower right radiator mount.
  6. Drain the intercooler system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) in Engine Cooling.
  7. Remove the auxiliary intercooler pump. Refer to «Coolant Pump Replacement - Charge Air Cooler»(ref-196980-S41610033062005101000000) in Engine Cooling.
  8. Remove the mounting cover from the charge air cooler pump and position the pump forward.
  9. Disconnect the electrical connector from the pressure transducer.
  10. Remove the compressor and condenser hose assembly bolt from the compressor.
  11. Remove the compressor and condenser hose assembly from the compressor.
  12. Remove and discard the sealing washers.
  13. Remove the compressor hose from the condenser.
  14. Remove and discard the seal washer.
  1. Route the compressor hose to the evaporator hose.
  2. Install new sealing washers on the compressor and condenser hose fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  3. Install the A/C compressor and condenser hose assembly to the compressor.
  4. Install the A/C compressor and condenser hose assembly bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  5. Install a new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  6. Install the compressor hose and bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  7. Connect the pressure transducer electrical connector.
  8. Install the auxiliary intercooler pump. Refer to «Coolant Pump Replacement - Charge Air Cooler»(ref-196980-S41610033062005101000000) in Engine Cooling.
  9. Install the lower right radiator mount.
  10. Install the charge cooler pump. Tighten: Tighten the bolts to 10 N.m (88 lb in).
  11. Lower the vehicle.
  12. Install a new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  13. Install the compressor hose and nut to the evaporator hose. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  14. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  15. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  16. Fill the intercooler system with coolant. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) in Engine Cooling.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Remove the condenser tube bolt and tube from the condenser.
  4. Remove and discard the sealing washers.
  5. Lower the vehicle.
  6. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-196955-S35764149722005101000000) in Engine Controls-2.2L (L61).
  7. Remove the condenser tube from the frame rail.
  8. Remove the condenser tube from the front of dash.
  9. Remove the condenser tube and evaporator hose from the TXV.
  10. Remove and discard the seal washer.
  1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  2. Install the condenser tube and evaporator hose to the TXV.
  3. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  4. Install the condenser tube to the front of dash. Tighten: Tighten the nut to 10 N.m (88 lb in).
  5. Install the condenser tube to the frame rail.
  6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-196955-S35764149722005101000000) in Engine Controls-2.2L (L61).
  7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  8. Install a new seal washer to the condenser tube. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  9. Install the condenser tube and bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  10. Lower the vehicle.
  11. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  12. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Remove the condenser tube bolt and tube from the condenser.
  4. Remove and discard the sealing washers.
  5. Lower the vehicle.
  6. Remove the condenser tube from the frame rail.
  7. Remove the condenser tube from the front of dash.
  8. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
  9. Remove and discard the seal washer.
  1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  2. Install the condenser tube and evaporator hose to the TXV.
  3. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  4. Install the condenser tube to the front of dash. Tighten: Tighten the nut to 10 N.m (88 lb in).
  5. Install the condenser tube to the frame rail.
  6. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  7. Install a new seal washer to the condenser tube. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  8. Install the condenser tube and bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  9. Lower the vehicle.
  10. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  11. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Remove the compressor hose from the evaporator hose.
  3. Remove and discard the seal washer.
  4. Remove the condenser tube and evaporator hose from the TXV.
  5. Remove and discard the seal washers.
  1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  2. Install the condenser tube and evaporator hose to the TXV.
  3. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  4. Install new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  5. Install the compressor hose and nut to the evaporator hose. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  6. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  7. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Remove the compressor hose from the evaporator hose.
  3. Remove and discard the seal washer.
  4. Remove the retainer clamp from the evaporator hose.
  5. Remove the condenser tube and the evaporator hose from the thermal expansion valve (TXV).
  6. Remove and discard the seal washers.
  1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  2. Install the condenser tube and evaporator hose to the TXV.
  3. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  4. Install the new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  5. Install the compressor hose and nut to the evaporator hose. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  6. Install the retainer clamp to the evaporator hose.
  7. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  8. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Remove the condenser tube and evaporator hose from the TXV.
  3. Remove and discard the seal washer.
  4. Remove the refrigerant filter from the condenser tube.
  1. Install the refrigerant filter into the condenser tube.
  2. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  3. Install the condenser tube and evaporator hose to the TXV.
  4. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  5. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  6. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .

Service Port Valve Core Replacement

Tools Required

  1. J 39400-A Halogen Leak Detector. See «Special Tools»(ref-197012-S41925114452005101000000) .
  2. J 46246 Valve Core Removal Tool. See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Remove the service port valve core using J 46246 or equivalent. See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Install the service port valve core using J 46246 or equivalent. See «Special Tools»(ref-197012-S41925114452005101000000) . 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-197012-S41979019262005101000000) .
  3. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Remove the condenser tube and evaporator hose from the TXV.
  3. Remove and discard the seal washers.
  4. Remove the TXV bolts.
  5. Remove the TXV.
  6. Remove and discard the seal washers.
  1. Install new seal washers to the evaporator core fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  2. Install the TXV.
  3. Install the TXV bolts. Tighten: Tighten the bolts to 7 N.m (62 lb in).
  4. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) .
  5. Install the condenser tube and evaporator hose to the TXV.
  6. Install the TXV nut. 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-197012-S41979019262005101000000) .
  8. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  2. Disconnect the electrical connector from the pressure sensor.
  3. Remove the pressure sensor from the compressor hose.
  4. Remove and discard the seal.
  1. Install a new seal in the pressure sensor.
  2. Install the pressure sensor to the compressor hose. Tighten: Tighten the pressure sensor to 5 N.m (44 lb in).
  3. Connect the pressure sensor electrical connector.
  4. Lower the vehicle.
  5. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Remove the compressor hose from the condenser.
  4. Remove the condenser tube from the condenser.
  5. Remove the condenser bolts.
  6. Slide the condenser down to disengage the upper mounting tabs from the radiator.
  7. Remove the right and left radiator side baffles.
  1. If replacing the condenser add the specified amount of PAG oil directly to the condenser. Refer to «Refrigerant System Capacities»(ref-197012-S00101949012005101000000) .
  2. Install the right and left radiator side baffles.
  3. Slide the condenser up to engage the upper mounting tabs into the radiator.
  4. Install the condenser bolts. Tighten: Tighten the bolts to 10 N.m (88 lb in).
  5. Install the compressor hose and new seal washer to the condenser. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) . Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  6. Install the condenser tube and new seal washer to the condenser. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) . Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  7. Lower the vehicle.
  8. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  9. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Remove the compressor hose from the condenser.
  4. Remove the condenser tube from the condenser.
  5. Remove the condenser bolts.
  6. Slide the condenser down to disengage the upper mounting tabs from the radiator.
  7. Remove the right and left radiator side baffles.
  1. If replacing the condenser add the specified amount of PAG oil directly to the condenser. Refer to «Refrigerant System Capacities»(ref-197012-S00101949012005101000000) .
  2. Install the right and left radiator side baffles.
  3. Slide the condenser up to engage the upper mounting tabs into the radiator brackets.
  4. Install the condenser bolts. Tighten: Tighten the bolts to 10 N.m (88 lb in).
  5. Install the compressor hose and new seal washer to the condenser. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) . Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  6. Install the condenser tube and new seal washer to the condenser. Refer to «Sealing Washer Replacement»(ref-197012-S14228903682005101000000) . Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  7. Lower the vehicle.
  8. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  9. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  1. Remove the HVAC module from the vehicle. Refer to «HVAC Module Assembly Replacement»(ref-197012-S12365138092005101000000) .
  2. Remove the fasteners from the heater core cover and remove the cover.
  3. Remove the heater core.
  4. Remove the lower HVAC case screws.
  5. Unsnap and open the passenger compartment filter door.
  6. Remove the lower HVAC case.
  7. Remove the evaporator core.
  1. Install the evaporator core into the HVAC module assembly.
  2. Install the lower HVAC case.
  3. Install the lower HVAC case screws. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
  4. Close and secure the passenger compartment filter door.
  5. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
  6. Install the heater core into the HVAC module.
  7. Install the heater core cover and the screws. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
  8. Replace the drain tube seal.
  9. Replace the front of dash seal.
  10. Inspect and replace the following HVAC module seals if damaged: The defrost duct seal The HVAC module to cross car duct seal The center air outlet duct seal The center floor air outlet duct seal The air inlet seal
  11. Install the HVAC module in the vehicle. Refer to «HVAC Module Assembly Replacement»(ref-197012-S12365138092005101000000) .
  12. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  13. Leak test the fittings using J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  14. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. Remove the HVAC module from the vehicle. Refer to «HVAC Module Assembly Replacement»(ref-197012-S12365138092005101000000) .
  2. Remove the heater core cover fasteners and cover.
  3. Remove the heater core.
  4. Remove the lower HVAC case screws.
  5. Unsnap and open the passenger compartment filter door.
  6. Remove the lower HVAC case.
  1. Install the lower HVAC case.
  2. Install the lower HVAC case screws. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
  3. Close and secure the passenger compartment filter door.
  4. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
  5. Install the heater core into the HVAC module.
  6. Install the heater core cover and fasteners. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
  7. Replace the drain tube seal.
  8. Replace the front of dash seal.
  9. Inspect and replace the HVAC module seals if damaged: The defrost duct seal The HVAC module to cross car duct seal The center air outlet duct seal The center floor air outlet duct seal The air inlet seal
  10. Install the HVAC module in the vehicle. Refer to «HVAC Module Assembly Replacement»(ref-197012-S12365138092005101000000) .
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .

HVAC Module Assembly Replacement

Tools Required

  1. J 39400-A Halogen Leak Detector. See «Special Tools»(ref-197012-S41925114452005101000000) .
  2. SA9111E Hose Clamp Pliers
CAUTIONWith a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-196956-S04090516432005101000000) in Engine Electrical.
  2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  3. Remove the surge tank cap.
  4. Place a drain pan below the heater hoses.
  5. Reposition the heater outlet hose clamp at the heater core using SA9111E .
  6. Remove the heater outlet hose from the heater core.
  7. Position the hose upright against the front of dash.
  8. Reposition the heater inlet hose clamp at the heater core using SA9111E .
  9. Remove the heater inlet hose from the heater core.
  10. Position the hose upright against the front of dash.
  11. Remove the condenser tube and evaporator hose from the TXV.
  12. Remove and discard the seal washers.
  13. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts.
  14. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage the duct from the HVAC module.
  15. Disconnect the blower motor connector.
  16. Disconnect the blower motor resistor electrical connector.
  17. Remove the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-196967-S02172948492005101000000) in Instrument Panel, Gages, and Console.
  18. Disconnect the recirculation actuator electrical connector.
  19. Remove the HVAC module from the vehicle.
  1. Replace the drain tube seal.
  2. Replace the front of dash seal.
  3. Inspect and replace the HVAC module seals if damaged: The defrost duct seal The HVAC module to cross car duct seal The center air outlet duct seal The center floor air outlet duct seal The air inlet seal
  4. Place the HVAC module in the vehicle. Align the HVAC module drain tube and front of dash studs to the vehicle.
  5. Connect the recirculation actuator electrical connector.
  6. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-196967-S02172948492005101000000) in Instrument Panel, Gages, and Console.
  7. Connect the blower motor connector.
  8. Connect the blower motor resistor electrical connector.
  9. Align the center floor duct with the HVAC module.
  10. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module.
  11. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts.
  12. Slide the center floor outlet duct down into position in the floor ducts.
  13. Install the heater outlet hose to the heater core.
  14. Reposition the hose clamp to secure the hose using SA9111E .
  15. Install the heater inlet hose to the heater core.
  16. Reposition the hose clamp to secure the hose using SA9111E .
  17. Install new sealing washers on the condenser tube and evaporator hose fittings.
  18. Install the condenser tube and evaporator hose to the TXV.
  19. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  20. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  21. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  22. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-196956-S04090516432005101000000) in Engine Electrical.
  23. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) in Engine Cooling.
  1. Remove the HVAC module from the vehicle. Refer to «HVAC Module Assembly Replacement»(ref-197012-S12365138092005101000000) .
  2. Remove the heater core cover screws and cover.
  3. Remove the heater core.
  4. Unsnap and open the passenger compartment filter door.
  5. Remove the lower HVAC case screws.
  6. Remove the lower HVAC case.
  7. Remove the evaporator core.
  1. If replacing the evaporator core, add PAG oil to the evaporator core. Refer to «Refrigerant System Capacities»(ref-197012-S00101949012005101000000) .
  2. Install new seal washers to the evaporator core fittings.
  3. Install the TXV.
  4. Install the TXV bolts. Tighten: Tighten the TXV bolts to 7 N.m (62 lb in).
  5. Install the foam seals to the evaporator core.
  6. Install the evaporator core into the HVAC module assembly.
  7. Install the lower HVAC case.
  8. Install the lower HVAC case screws. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
  9. Close and secure the passenger compartment filter door.
  10. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
  11. Install the heater core into the HVAC module.
  12. Install the heater core cover.
  13. Install the heater core cover screws. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
  14. Install the HVAC module into the vehicle. Refer to «HVAC Module Assembly Replacement»(ref-197012-S12365138092005101000000) .
  15. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-197012-S41979019262005101000000) .
  16. Leak test the fittings using the J 39400-A . See «Special Tools»(ref-197012-S41925114452005101000000) .
  17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-196956-S04090516432005101000000) in Engine Electrical.
  18. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) in Engine Cooling.
  1. Remove the surge tank cap.
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Place a drain pan under the water pump drain port.
  4. Loosen the water pump drain bolt (1) and drain the coolant from the water pump.
  5. Close and tighten the water pump drain bolt (1). Tighten: Tighten the bolt to 10 N.m (88 lb in).
  6. Lower the vehicle.
  7. Reposition the heater inlet hose clamp at the heater core using SA9111E .
  8. Remove the heater inlet hose from the heater core.
  9. Reposition the heater inlet hose clamp at the engine using SA9111E .
  10. Remove the heater inlet hose from the engine.
  1. Install the heater inlet hose to the heater core.
  2. Reposition the hose clamp to secure the hose using SA9111E .
  3. Install the heater inlet hose to the engine.
  4. Reposition the hose clamp to secure the hose using SA9111E .
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) in Engine Cooling.
  1. Remove the surge tank cap.
  2. Slide a drain pan under the front of the dashboard under the heater inlet hose.
  3. Reposition the heater inlet hose clamp at the heater core using SA9111E .
  4. Remove the heater inlet hose from the heater core and tilt the hose downward toward the drain pan to drain the coolant from the hose.
  5. Reposition the heater inlet hose clamp at the engine using SA9111E .
  6. Remove the heater inlet hose from the engine.
  1. Install the heater inlet hose to the heater core.
  2. Reposition the hose clamp to secure the hose using SA9111E .
  3. Install the heater inlet hose to the engine.
  4. Reposition the hose clamp to secure the hose using SA9111E .
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) in Engine Cooling.
  6. Remove the drain pan from under the vehicle.
  1. Remove the surge tank cap.
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Place a drain pan under the water pump drain port.
  4. Loosen the water pump drain bolt (1) and drain the coolant from the water pump.
  5. Close and tighten the water pump drain bolt (1). Tighten: Tighten the bolt to 10 N.m (88 lb in).
  6. Lower the vehicle.
  7. Reposition the heater outlet hose clamp at the heater core using SA9111E .
  8. Remove the heater outlet hose from the heater core.
  9. Reposition the hose heater outlet hose clamp at the engine using SA9111E .
  10. Remove the heater outlet hose from the engine.
  1. Install the heater outlet hose to the heater core.
  2. Reposition the hose clamp to secure the hose using SA9111E .
  3. Install the heater outlet hose to the engine.
  4. Reposition the hose clamp to secure the hose using SA9111E .
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) in Engine Cooling.
  1. Remove the surge tank cap.
  2. Slide a drain pan under the heater hoses near the front of the dashboard.
  3. Reposition the heater outlet hose clamp at the heater core using SA9111E .
  4. Remove the heater outlet hose from the heater core and tilt the hose downward toward the drain pan to drain the coolant from the hose.
  5. Reposition the hose heater outlet hose clamp at the engine using SA9111E .
  6. Remove the heater outlet hose from the engine.
  1. Install the heater outlet hose to the heater core.
  2. Reposition the hose clamp to secure the hose using SA9111E .
  3. Install the heater outlet hose to the engine.
  4. Reposition the hose clamp to secure the hose using SA9111E .
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) in Engine Cooling.
  6. Remove the drain pan from under the vehicle.
  1. Open the I/P compartment. The access door for the passenger compartment air filter is located behind the glove box.
  2. Tilt the I/P compartment door down by squeezing in on each side of the bin until the door stops can be removed from the tracks.
  3. Lower the I/P compartment completely.
  4. Open the passenger compartment filter door by reaching through the opening in the rear of the I/P compartment and raising the tab until the door can be opened downward.
  5. Remove the filter by sliding the filter out of the passenger compartment filter housing.
  1. Install the new filter by sliding the filter into the passenger compartment filter housing.
  2. Close the passenger compartment filter door and snap the tab down to latch the door.
  3. Raise the I/P compartment door until the door stops contact the frame. Slowly raise the door until the doorstops snap into their tracks.
  1. Disconnect the blower motor resistor electrical connector.
  2. Unsnap the blower motor resistor from the HVAC module and remove.
  1. Snap the blower motor resistor into the HVAC module.
  2. Connect the blower motor electrical connector.
  1. Disconnect the blower motor electrical connector.
  2. Remove the lower blower motor cover retaining screws.
  3. Remove the lower blower motor cover.
  4. Remove the blower motor nuts.
  5. Remove the blower motor and cup from the lower case by cutting through the case between the circular ribs around the motor with a sharp utility knife.
  6. Release the blower motor retaining tab and remove the motor from the cup.
  1. Install the blower motor (1) into the motor cup (2) that was cut out of the lower case.
  2. Install the blower motor nuts (3). Tighten: Tighten the nuts to 2.4 N.m (21 lb in).
  3. Attach the service ring (4) to the motor cup (2) with the screws (5) included in the kit. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
  4. Install the blower motor and service ring into the HVAC module using the screws (5) included in the kit. Make certain the blower motor electrical connector is pointing rearward in the vehicle. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
  5. Install the lower blower motor cover.
  6. Install the lower blower motor cover retaining screws. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
  7. Connect the blower motor electrical connector.
  1. Remove the instrument panel (I/P) trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Left»(ref-196967-S23312903802005101000000) or «Instrument Panel (I/P) Trim Panel Replacement - Right»(ref-196967-S38417716842005101000000) in Instrument Panel, Gages, and Console.
  2. Remove the air outlet from the I/P trim panel.
  1. Install the air outlet to the I/P trim panel.
  2. Install the instrument panel (I/P) trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Left»(ref-196967-S23312903802005101000000) or «Instrument Panel (I/P) Trim Panel Replacement - Right»(ref-196967-S38417716842005101000000) in Instrument Panel, Gages, and Console.
  1. Remove the left instrument panel (I/P) trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Left»(ref-196967-S23312903802005101000000) in Instrument Panel, Gages, and Console.
  2. Remove the outer air duct screw and duct.
  1. Install the outer air duct.
  2. Install the outer air duct screw. Tighten: Tighten the air outlet duct screw to 2.5 N.m (22 lb in).
  3. Install the left instrument panel (I/P) trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Left»(ref-196967-S23312903802005101000000) in Instrument Panel, Gages, and Console.
  1. Remove the right instrument panel (I/P) trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Right»(ref-196967-S38417716842005101000000) in Instrument Panel, Gages, and Console.
  2. Remove the outer air duct screw and duct.
  1. Install the outer air duct.
  2. Install the outer air duct screw. Tighten: Tighten the air outlet duct screw to 2.5 N.m (22 lb in).
  3. Install the right instrument panel (I/P) trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Right»(ref-196967-S38417716842005101000000) in Instrument Panel, Gages, and Console.
  1. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts.
  2. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage the duct from the HVAC module.
  1. Align the center floor duct with the HVAC module.
  2. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module.
  3. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts.
  4. Slide the center floor outlet duct down into position in the floor ducts.
  1. Remove the instrument panel (I/P) center trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(ref-196967-S40219481442005101000000) in Instrument Panel, Gages, and Console.
  2. Remove the center air outlet duct screws and duct.
  1. Install the center air outlet duct.
  2. Install the center air outlet screws. Tighten: Tighten the center air outlet duct screws to 2.5 N.m (22 lb in).
  3. Install the instrument panel (I/P) center trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(ref-196967-S40219481442005101000000) in Instrument Panel, Gages, and Console.
  1. Remove the instrument panel (I/P) retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-196967-S14306319292005101000000) in Instrument Panel, Gages, and Console.
  2. Unsnap the defroster duct from the HVAC module and cross car beam. Bend the cluster wire harness tab on the cross car beam in order to remove the duct.
  1. Align the defroster duct with the HVAC module and snap into place.
  2. If the cluster wire harness tab on the cross car beam was bent during removal, bend the tab back into position.
  3. Install the I/P retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-196967-S14306319292005101000000) in Instrument Panel, Gages, and Console.
  1. Remove the defroster grille and place face down on a clean surface. Refer to «Defroster Grille Replacement»(ref-196967-S40327281042005101000000) in Instrument Panel, Gages, and Console.
  2. Remove the side window defroster duct screws and duct.
  1. Install the side window defroster duct.
  2. Install the side window defroster duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  3. Install the defroster grille. Refer to «Defroster Grille Replacement»(ref-196967-S40327281042005101000000) in Instrument Panel, Gages, and Console.
  1. Remove the defroster grille and place face down on a clean surface. Refer to «Defroster Grille Replacement»(ref-196967-S40327281042005101000000) in Instrument Panel, Gages, and Console.
  2. Remove the side window defroster duct screws and duct.
  1. Install the side window defroster duct.
  2. Install the side window defroster duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
  3. Install the defroster grille. Refer to «Defroster Grille Replacement»(ref-196967-S40327281042005101000000) in Instrument Panel, Gages, and Console.
  1. Remove the front seat. Refer to «Seat Replacement - Front Bucket»(ref-196986-S39525070032005101000000) in Seats.
  2. Remove the front carpet retainer.
  3. Pull the carpet up to access the floor duct.
  4. Unsnap the floor duct from the floor support beam. Disengage the floor duct from the center floor outlet duct and remove from the vehicle.
  1. Align the floor duct with the center floor outlet duct.
  2. Align the floor duct with the floor support beam and snap into place.
  3. Reposition the carpet.
  4. Install the carpet retainer.
  5. Install the front seat. Refer to «Seat Replacement - Front Bucket»(ref-196986-S39525070032005101000000) in Seats.
  1. Remove the front seat. Refer to «Seat Replacement - Front Bucket»(ref-196986-S39525070032005101000000) in Seats.
  2. Remove the front carpet retainer.
  3. Pull the carpet up to access the floor duct.
  4. Unsnap the floor duct from the floor support beam. Disengage the floor duct from the center floor outlet duct and remove from the vehicle.
  1. Align the floor duct with the center floor outlet duct.
  2. Align the floor duct with the floor support beam and snap into place.
  3. Reposition the carpet.
  4. Install the carpet retainer.
  5. Install the front seat. Refer to «Seat Replacement - Front Bucket»(ref-196986-S39525070032005101000000) in Seats.
  1. Remove the body control module (BCM) from the vehicle. Refer to «Body Control Module Replacement»(ref-196943-S15091484502005101000000) in Computer/Integrating Systems.
  2. Pull back the carpet at the bottom of the left instrument panel (I/P) center support bracket and remove the left I/P center support bracket nuts.
  3. Remove the left I/P center support bracket.
  4. Remove the accelerator control pedal from the front of the dash and position out of the way. Refer to «Accelerator Controls Pedal Replacement»(ref-196955-S13382517492005101000000) in Engine Controls - 2.2L (L61).
  5. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts.
  6. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage it from the HVAC module.
  7. Remove the heater core cover screws.
  8. Pull the heater core cover down just enough to clear the locating pins from the HVAC module. Slide the heater core cover rearward until the drain tube clears the front of dash. Slide the heater core cover down, rearward, and to the right to remove.
  1. Install a new drain tube seal onto the drain tube.
  2. Install the heater core cover from the right side. Slide up and forward into position. Align the drain tube with the hole in the front of dash. Raise the heater core cover into position while aligning holes with the locating pins from the HVAC module.
  3. Install the heater core cover screws. Tighten: Tighten the heater core cover screws to 1.8 N.m (15 lb in).
  4. Align the center floor duct with the HVAC module.
  5. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module.
  6. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts.
  7. Slide the center floor outlet duct down into position in the floor ducts.
  8. Install the accelerator control pedal. Refer to «Accelerator Controls Pedal Replacement»(ref-196955-S13382517492005101000000) in Engine Controls - 2.2L (L61).
  9. Pull back the carpet and place the left center support bracket into position.
  10. Install the left center support bracket nuts. Tighten: Tighten the left center support bracket nuts to 10 N.m (88 lb in).
  11. Install the BCM to the vehicle. Refer to «Body Control Module Replacement»(ref-196943-S15091484502005101000000) in Computer/Integrating Systems.
  1. Remove the surge tank cap.
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  3. Place a drain pan under the water pump drain port.
  4. Loosen the water pump drain bolt and drain the coolant from the water pump.
  5. Close and tighten the water pump drain bolt. Tighten: Tighten the water pump drain bolt to 10 N.m (88 lb in).
  6. Lower the vehicle.
  7. Reposition the heater outlet hose clamp at the heater core using SA9111E .
  8. Remove the heater outlet hose from the heater core.
  9. Reposition the heater inlet hose clamp at the heater core using SA9111E .
  10. Remove the heater inlet hose from the heater core.
  11. Remove the heater core cover. Refer to «Heater Core Cover Replacement»(ref-197012-S09076367582005101000000) .
  12. Remove the heater core.
  1. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
  2. Install the heater core into the HVAC module.
  3. Install the heater core cover. Refer to «Heater Core Cover Replacement»(ref-197012-S09076367582005101000000) .
  4. Install the heater outlet hose to the heater core.
  5. Install the hose clamp to secure the hose using SA9111E .
  6. Install the heater inlet hose to the heater core.
  7. Install the hose clamp to secure the hose using SA9111E .
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) in Engine Cooling.

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