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

Automatic HVAC System 30 illustrations ~448 words

Compressor Replacement (LNF)

CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . Remove the drive belt. Refer to Drive Belt Replacement .
1A/C Compressor and Condenser Hose Assembly Bolt NOTE: Refer to Fastener Notice . Tighten: 22 N.m (16 lb ft)
2Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3A/C Compressor Bolt (Qty: 3) Tip: Tighten bolts in sequence. Tighten: 22 N.m (16 lb ft)
4A/C Compressor Assembly
NOTE
Refer to Fastener Notice .

Compressor Replacement (LNF)

Removal Procedure

  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.

Installation Procedure

  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.

Scheme 2

Scheme 2: Compressor Hose Assembly Replacement (LE5)
Scheme 2: Compressor Hose Assembly Replacement (LE5)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1A/C Compressor and Condenser Hose Assembly Nut NOTE: Refer to Fastener Notice . Tip: A/C compressor hose to A/C evaporator hose Tighten: 9 N.m (80 lb in)
2Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3A/C Compressor and Condenser Hose Assembly Nut Tip: A/C compressor hose to A/C condenser. Tighten: 9 N.m (80 lb in)
4Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
5A/C Compressor and Condenser Hose Assembly Bolt Tighten: 22 N.m (16 lb ft)
6Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
7A/C Compressor and Condenser Hose Assembly
NOTE
Refer to Fastener Notice .

Compressor Hose Assembly Replacement (LE5)

Compressor Hose Assembly Replacement (LNF)

CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1A/C Compressor and Condenser Hose Assembly Nut NOTE: Refer to Fastener Notice . Tip: A/C compressor hose to A/C evaporator hose Tighten: 9 N.m (80 lb in)
2Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3A/C Compressor and Condenser Hose Assembly Nut Tip: A/C compressor hose to A/C condenser Tighten: 9 N.m (80 lb in)
4Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
5A/C Compressor and Condenser Hose Assembly Bolt Tighten: 22 N.m (16 lb ft)
6Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
7A/C Compressor and Condenser Hose Assembly
NOTE
Refer to Fastener Notice .

Compressor Hose Assembly Replacement (LNF)

Scheme 3

Scheme 3: Condenser Tube Replacement (LE5)
Scheme 3: Condenser Tube Replacement (LE5)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1A/C Condenser Tube Assembly Nut NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3Push Pin Retainer
4A/C Condenser Tube Assembly Nut Tighten: 9 N.m (80 lb in)
5Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
6A/C Condenser Tube Assembly
NOTE
Refer to Fastener Notice .

Condenser Tube Replacement (LE5)

Scheme 4

Scheme 4: Condenser Tube Replacement (LNF)
Scheme 4: Condenser Tube Replacement (LNF)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1A/C Condenser Tube Assembly Nut NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3Push Pin Retainer
4A/C Condenser Tube Assembly Nut Tighten: 9 N.m (80 lb in)
5Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
6A/C Condenser Tube Assembly
NOTE
Refer to Fastener Notice .

Condenser Tube Replacement (LNF)

Scheme 5

Scheme 5: Evaporator Tube Replacement (LE5)
Scheme 5: Evaporator Tube Replacement (LE5)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement .
1A/C Condenser Tube Assembly Nut NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
3A/C Compressor and Condenser Hose Assembly Nut Tighten: 9 N.m (80 lb in)
4Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
5A/C Evaporator Hose Assembly Clip Nut (Qty: 2) Tighten: 9 N.m (80 lb in)
6A/C Evaporator Hose Assembly Bolt (Qty: 2) Tighten: 16 N.m (12 lb ft)
7Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
8A/C Evaporator Hose Assembly
NOTE
Refer to Fastener Notice .

Evaporator Tube Replacement (LE5)

Scheme 6

Scheme 6: Evaporator Tube Replacement (LNF)
Scheme 6: Evaporator Tube Replacement (LNF)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement .
1A/C Condenser Tube Assembly Nut NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
3A/C Compressor and Condenser Hose Assembly Nut Tighten: 9 N.m (80 lb in)
4Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
5A/C Evaporator Hose Assembly Clip Nut (Qty: 2) Tighten: 9 N.m (80 lb in)
6A/C Evaporator Hose Assembly Bolt (Qty: 2) Tighten: 16 N.m (12 lb ft)
7Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
8A/C Evaporator Hose Assembly
NOTE
Refer to Fastener Notice .

Evaporator Tube Replacement (LNF)

  1. Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(ref-269779-S20502390932007110200000) .
  2. Remove the A/C refrigerant valve (2).
  3. Remove and discard the O-ring seal (3).
  1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil.
  2. Install the O-ring seal (3) onto the valve if necessary.
  3. Install the A/C refrigerant valve (2). Tighten: Tighten the valve to 11 N.m (98 lb in).
  4. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-269779-S20502390932007110200000) .
  5. Leak test the fitting valve area using the J 39400-A .
  6. Install the service port cap (1).

Scheme 7

Scheme 7: Receiver Dehydrator Replacement (LE5)
Scheme 7: Receiver Dehydrator Replacement (LE5)
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 lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
1Receiver Dehydrator Screw Tighten: 1.5 N.m (13 lb in)
2Receiver Dehydrator Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
3Receiver Dehydrator O-Ring Tip: Remove and discard the O-rings.
4Receiver and Dehydrator Assembly, A/C
NOTE
Refer to Fastener Notice .

Receiver Dehydrator Replacement (LE5)

Scheme 8

Scheme 8: Receiver Dehydrator Replacement (LNF)
Scheme 8: Receiver Dehydrator Replacement (LNF)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the charge air cooler. Refer to Charge Air Cooler Replacement . Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
1Receiver Dehydrator Screw NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2Receiver Dehydrator Screw Tighten: 1.5 N.m (13 lb in)
3Receiver Dehydrator O-Ring Tip: Remove and discard the O-rings.
4Receiver and Dehydrator Assembly, A/C
NOTE
Refer to Fastener Notice .

Receiver Dehydrator Replacement (LNF)

Scheme 9

Scheme 9: Thermal Expansion Valve Replacement
Scheme 9: Thermal Expansion Valve Replacement
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Recover the A/C system. Refer to Refrigerant Recovery and Recharging .
1A/C Compressor Tube Assembly - Nut Tighten: 16 N.m (12 lb ft)
2Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
3Thermal Expansion Valve Bolt Tighten: 16 N.m (12 lb ft)
4Sealing Washer Tip: Remove and discard the sealing washer. Refer to Sealing Washer Replacement .
5Thermal Expansion Valve
NOTE
Refer to Fastener Notice .

Thermal Expansion Valve Replacement

Scheme 10

Scheme 10: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement
Scheme 10: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Disconnect the electrical connector from the A/C pressure sensor.
1A/C Refrigerant Pressure Sensor Tighten: 5 N.m (44 lb in)
2O-Ring, Seal Tip: Remove and discard O-ring.
NOTE
Refer to Fastener Notice .

Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement

Scheme 11

Scheme 11: Evaporator Temperature Sensor Replacement
Scheme 11: Evaporator Temperature Sensor Replacement
CalloutComponent Name
Preliminary Procedure: Remove the instrument panel (I/P) carrier. Refer to Instrument Panel Carrier Replacement .
1Heater Core Cover Screw (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2Heater Core Cover
3Air Conditioning Refrigerant Temperature Sensor Tip: Disconnect the air conditioning refrigerant temperature sensor electrical connector. Twist the air conditioning refrigerant temperature sensor to the left to release and pull upward.
NOTE
Refer to Fastener Notice .

Evaporator Temperature Sensor Replacement

Scheme 12

Scheme 12: Condenser Replacement (LE5)
Scheme 12: Condenser Replacement (LE5)
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 lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
1A/C Condenser Tube Nut Tighten: 9 N.m (80 lb in)
2Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3A/C Compressor and Condenser Hose Nut Tighten: 9 N.m (80 lb in)
4Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
5A/C Condenser Bolt Tighten: 9 N.m (80 lb in)
6Radiator Assembly Bolt Tighten: 25 N.m (18 lb ft)
7Receiver Dehydrator Assembly Bolt Tighten: 6 N.m (53 lb in)
8Receiver Dehydrator Assembly Bolt Tighten: 6 N.m (53 lb in)
9O-Ring Tip: Remove and discard O-rings.
10A/C Receiver Dehydrator Assembly
11A/C Condenser Assembly
NOTE
Refer to Fastener Notice .

Condenser Replacement (LE5)

Scheme 13

Scheme 13: Condenser Replacement (LNF)
Scheme 13: Condenser Replacement (LNF)
CalloutComponent Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement . Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement . Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
1A/C Condenser Tube Nut NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
3A/C Compressor and Condenser Hose Nut Tighten: 9 N.m (80 lb in)
4Sealing Washer Tip: Remove and discard sealing washer. Refer to Sealing Washer Replacement .
5A/C Condenser Bolt Tighten: 9 N.m (80 lb in)
6Radiator Assembly Bolt Tighten: 25 N.m (18 lb ft)
7Receiver Dehydrator Assembly Bolt Tighten: 6 N.m (53 lb in)
8Receiver Dehydrator Assembly Bolt Tighten: 6 N.m (53 lb in)
9O-Ring Tip: Remove and discard O-rings.
10A/C Receiver Dehydrator Assembly
11A/C Condenser Assembly
NOTE
Refer to Fastener Notice .

Condenser Replacement (LNF)

Scheme 14

Scheme 14: Air Conditioning (A/C) Evaporator Case Assembly Replacement
Scheme 14: Air Conditioning (A/C) Evaporator Case Assembly Replacement
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement . Remove the heater core cover. Refer to Heater Core Cover Replacement . Remove the air inlet assembly. Refer to Air Inlet Assembly Replacement . Note routing of electrical wiring to ensure proper installation. Disconnect electrical connectors.
1Rear Air Outlet Duct Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
2Rear Air Outlet Duct
3Evaporator Case Drain Tube Seal
4Evaporator Case Assembly Screw (Qty: 10) Tighten: 1.5 N.m (13 lb in)
5Air Distributor
6Evaporator Case - Lower
7Evaporator Case - Upper
8Evaporator Core
9Blower Motor Resistor Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
10Blower Motor Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
11Blower Motor Assembly
12Air Inlet Housing Baffle
NOTE
Refer to Fastener Notice .

Air Conditioning (A/C) Evaporator Case Assembly Replacement

Scheme 15

Scheme 15: HVAC Module Assembly Replacement
Scheme 15: HVAC Module Assembly Replacement
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the evaporator tube from the thermal expansion valve. Refer to Thermal Expansion Valve Replacement . Remove the heater inlet hose from the heater core. Refer to Heater Inlet Hose Replacement (LE5) or Heater Inlet Hose Replacement (LNF) . Remove the heater outlet hose from the heater core. Refer to Heater Outlet Hose Replacement (LE5) or Heater Outlet Hose Replacement (LNF) . Remove the instrument panel (I/P) tie bar. Refer to Instrument Panel Tie Bar Replacement . Disconnect the HVAC module assembly electrical connectors.
1HVAC Module Assembly Nut (Qty: 5) NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2HVAC Module Assembly Tip: Note routing of wiring harness to ensure proper installation.
NOTE
Refer to Fastener Notice .

HVAC Module Assembly Replacement

Scheme 16

Scheme 16: Evaporator Core Replacement
Scheme 16: Evaporator Core Replacement
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
1Evaporator Case Seal
2Thermal Expansion Valve Bolt (Qty: 2) Tighten: 16 N.m (12 lb ft)
3Thermal Expansion Valve
4Sealing Washer Tip: Remove and discard seals. Refer to Sealing Washer Replacement .
5Rear Air Outlet Duct Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
6Rear Air Outlet Duct
7Evaporator Case Assembly Screw (Qty: 9) Tighten: 1.5 N.m (13 lb in)
8Evaporator Lower Case
9Evaporator Core
NOTE
Refer to Fastener Notice .

Evaporator Core Replacement

Scheme 17

Scheme 17: Heater Inlet Hose Replacement (LE5)
Scheme 17: Heater Inlet Hose Replacement (LE5)
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
1Heater Inlet Hose Assembly Using the SA9111E reposition the heater inlet hose clamp. See Special Tools .

Heater Inlet Hose Replacement (LE5)

Scheme 18

Scheme 18: Heater Inlet Hose Replacement (LNF)
Scheme 18: Heater Inlet Hose Replacement (LNF)
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
1Heater Inlet Hose Assembly Using SA9111E reposition the heater inlet hose clamp. See Special Tools .

Heater Inlet Hose Replacement (LNF)

Scheme 19

Scheme 19: Heater Outlet Hose Replacement (LE5)
Scheme 19: Heater Outlet Hose Replacement (LE5)
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
1Heater Outlet Hose Assembly Using SA9111E reposition the heater outlet hose clamp. See Special Tools .

Heater Outlet Hose Replacement (LE5)

Scheme 20

Scheme 20: Heater Outlet Hose Replacement (LNF)
Scheme 20: Heater Outlet Hose Replacement (LNF)
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
1Heater Outlet Hose Assembly Using SA9111E reposition the heater outlet hose clamp. See Special Tools .

Heater Outlet Hose Replacement (LNF)

Scheme 21

Scheme 21: Air Inlet Assembly Replacement
Scheme 21: Air Inlet Assembly Replacement
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
1Air Inlet Housing Screw (Qty: 6) Tighten: 1.5 N.m (13 lb in)
2Mode Actuator Screw (Qty: 3) Tighten: 1.5 N.m (13 lb in)
3Mode Actuator
4Air Inlet Housing
NOTE
Refer to Fastener Notice .

Air Inlet Assembly Replacement

Scheme 22

Scheme 22: Air Inlet Housing Front Panel Replacement
Scheme 22: Air Inlet Housing Front Panel Replacement
CalloutComponent Name
Preliminary Procedures Remove the 3 hold down bolts for the underhood electrical center and position aside. Refer to Underhood Electrical Center or Junction Block Replacement . Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
1Air Inlet Housing Nuts (Qty: 5) NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Air Inlet Housing Front Panel Assembly
NOTE
Refer to Fastener Notice .

Air Inlet Housing Front Panel Replacement

Scheme 23

Scheme 23: Blower Motor Resistor Replacement
Scheme 23: Blower Motor Resistor Replacement
CalloutComponent Name
Preliminary Procedures Remove the I/P compartment. Refer to Instrument Panel Compartment Replacement . 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 .

Blower Motor Resistor Replacement

Scheme 24

Scheme 24: Blower Motor Replacement
Scheme 24: Blower Motor Replacement
CalloutComponent Name
Preliminary Procedures Remove the instrument panel (I/P) compartment. Refer to Instrument Panel Compartment Replacement . 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
3Blower Motor Screw (Qty: 3) Tighten: 1.5 N.m (13 lb in)
4Blower Motor Assembly
NOTE
Refer to Fastener Notice .

Blower Motor Replacement

Scheme 25

Scheme 25: Side Window Air Outlet Replacement
Scheme 25: Side Window Air Outlet Replacement
CalloutComponent Name
Preliminary Procedures: Remove the instrument panel (I/P) upper trim panel. Refer to Instrument Panel Upper Trim Panel Replacement .
1Side Window Defogger Outlet Grille - RH Procedure: Squeeze the tabs on the back of the outlet grille to release it from the trim panel.
2Side Window Defogger Outlet Grille - LH Procedure: Squeeze the tabs on the back of the outlet grille to release it from the trim panel.

Side Window Air Outlet Replacement

Scheme 26

Scheme 26: Instrument Panel Outer Air Outlet Replacement - Left Side
Scheme 26: Instrument Panel Outer Air Outlet Replacement - Left Side
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedures: Remove the knee bolster. Refer to Knee Bolster Replacement .
1Instrument Panel Outer Air Outlet Grille Assembly - Left

Instrument Panel Outer Air Outlet Replacement - Left Side

Scheme 27

Scheme 27: Instrument Panel Center Air Outlet Replacement
Scheme 27: Instrument Panel Center Air Outlet Replacement
CalloutComponent Name
Preliminary Procedure: Remove the instrument panel (I/P) accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement .
1Air Outlet Center Grille - RH
2Air Outlet Center Grille - LH

Instrument Panel Center Air Outlet Replacement

Scheme 28

Scheme 28: Instrument Panel Outer Air Outlet Replacement - Right Side
Scheme 28: Instrument Panel Outer Air Outlet Replacement - Right Side
CalloutComponent Name
Preliminary Procedure: Remove the instrument panel (I/P) compartment door frame. Refer to Instrument Panel Compartment Door Opening Frame Replacement .
1Instrument Panel Outer Air Outlet Grille Assembly - Right

Instrument Panel Outer Air Outlet Replacement - Right Side

Scheme 29

Scheme 29: Air Distributor Duct Replacement
Scheme 29: Air Distributor Duct Replacement
CalloutComponent Name
Preliminary Procedures Remove the instrument panel (I/P) carrier. Refer to Instrument Panel Carrier Replacement . IMPORTANT: Pull the tie bar far enough back for the air distribution duct to clear the opening. Remove the I/P tie bar. Refer to Instrument Panel Tie Bar Replacement .
1Distributor Air Nut (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 2.5 N.m (22 lb in)
2Distributor Air Nut (Qty: 3) Tighten: 2.5 N.m (22 lb in)
3Distributor Air Bolt Tighten: 2.5 N.m (22 lb in)
4Air Distributor
IMPORTANT
Pull the tie bar far enough back for the air distribution duct to clear the opening.
NOTE
Refer to Fastener Notice .

Air Distributor Duct Replacement

Scheme 30

Scheme 30: Heater Core Cover Replacement
Scheme 30: Heater Core Cover Replacement
CalloutComponent Name
Preliminary Procedure: Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
1Heater Core Cover Screw (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 1.5 N.m (13 lb in)
2Heater Core Cover
NOTE
Refer to Fastener Notice .

Heater Core Cover Replacement

Scheme 31

Scheme 31: Heater Core Replacement
Scheme 31: Heater Core Replacement
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement . Disconnect the actuator electrical connectors from the recirculation case.
1Air Outlet Duct Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
2Air Outlet Duct
3Heater Core Cover Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in)
4Heater Core Cover
5Heater Core Pass Through Seal
6Air Distribution Case Screw (Qty: 5) Tighten: 1.5 N.m (13 lb in)
7Air Distribution Case
8Heater Core
NOTE
Refer to Fastener Notice .

Heater Core Replacement

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