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

Automatic HVAC System ~10297 words

Removal

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-188814-S14277354852005090200000) in Engine Mechanical - 2.2L (L61).
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  4. Disconnect the electrical connector from the compressor.
  5. Remove the compressor hose bolt from the compressor.
  6. Remove the compressor hose from the compressor.
  7. Remove and discard the O-rings from the compressor. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  8. Install a shipping cap to the compressor hose to prevent moisture or contamination from entering the A/C system.
  9. Install a shipping cap to the compressor to prevent oil spillage during compressor removal.
  10. Remove the compressor bolts from the engine.
  11. Remove the compressor from the vehicle.

Installation

  1. If replacing the compressor, refer to «Compressor Oil Balancing»(ref-188838-S13697078132005090200000) .
  2. Install a shipping cap to the compressor to prevent oil spillage during installation.
  3. Install the compressor to the vehicle.
  4. Install the compressor bolts to the engine. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
  5. Remove the shipping caps from the compressor and the compressor hose.
  6. Install new O-rings to the compressor. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  7. Install the compressor hose to the compressor.
  8. Install the compressor hose bolt to the compressor. Tighten: Tighten the bolt to 27 N.m (20 lb ft).
  9. Connect the electrical connector to the compressor.
  10. Install the drive belt. Refer to «Drive Belt Replacement»(ref-188814-S14277354852005090200000) in Engine Mechanical - 2.2L (L61).
  11. Lower vehicle.
  12. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  13. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
IMPORTANTPerforming this procedure will require replacement of the forward engine frame bolts.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-188786-S18482282612005090200000) in Engine Controls - 3.5L (L66).
  3. Remove the accessory drive belt. Refer to «Drive Belt Replacement»(ref-188818-S03085051622005090200000) in Engine Mechanical - 3.5L (L66).
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  5. Disconnect the electrical connector from the compressor.
  6. Remove the compressor hose bolt from the compressor.
  7. Remove the compressor hose from the compressor.
  8. Remove and discard the O-rings from the compressor. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  9. Install a cap to the compressor hose to prevent moisture or contamination from entering the A/C system.
  10. Place an adjustable jack stand or a lifting device under the front edge of the engine frame.
  11. Loosen, but do not remove, the front engine frame mounting bolts.
  12. Lower the forward edge of the engine frame approximately 12.7 mm (0.5 in).
  13. Remove the compressor bolts from the engine.
  14. Remove the compressor from the vehicle.
  1. If replacing the compressor, refer to «Compressor Oil Balancing»(ref-188838-S13697078132005090200000) .
  2. Install the compressor to the vehicle.
  3. Install the compressor bolts to the engine. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
  4. Raise the forward edge of the engine frame.
  5. Remove and discard the right hand front engine frame bolt.
  6. Install a new right hand front engine frame bolt.
  7. Remove and discard the left hand front engine frame bolt.
  8. Install a new left hand front engine frame bolt.
  9. Tighten the engine frame bolts to the body. Tighten: Tighten the bolts to 155 N.m (114 lb ft).
  10. Remove the adjustable jack stand or lifting device from the front edge of the engine frame.
  11. Remove the caps from the compressor and the compressor hose.
  12. Install new O-rings to the compressor. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  13. Install the compressor hose to the compressor.
  14. Install the compressor hose bolt to the compressor. Tighten: Tighten the bolt to 27 N.m (20 lb ft).
  15. Connect the electrical connector to the compressor.
  16. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  17. Install the accessory drive belt. Refer to «Drive Belt Replacement»(ref-188818-S03085051622005090200000) in Engine Mechanical - 3.5L (L66).
  18. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-188786-S18482282612005090200000) in Engine Controls - 3.5L (L66).
  19. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  20. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .

Removal Procedure

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  2. Cut the wire harness leads 1 to the clutch coil.
  3. Remove the electrical connector from the clutch coil bracket.
  4. Remove the thermal protection switch (TPS) retainer bolt from the compressor.
  5. Remove the TPS retainer from the compressor.
  6. Remove the TPS assembly from the compressor. It may be necessary to gently pry the TPS with a flat bladed tool.

Installation Procedure

  1. Measure and cut the new TPS assembly to the proper length.
  2. Remove 9.5 mm (3/8 in) of insulation from the ends of the TPS assembly and the wire harness.
  3. Position the stripped ends of wire in the appropriate splice sleeve found in J 44020 .
  4. Crimp the splices using an approved crimping tool.
  5. Gently tug on the wires to ensure proper crimping.
  6. Apply heat 1 to the splice joints until glue 2 flows from the splice sleeves.
  7. Clean the TPS pocket of any foreign material.
  8. Apply Saturn thermal conductive sealant P/N 22681632 to the TPS pocket.
  9. Install the TPS to the TPS pocket on the compressor.
  10. Remove any excess sealant from around the switch.
  11. Install the TPS retainer to the compressor.
  12. Install the TPS retainer bolt to the compressor. Tighten: Tighten the bolt to 6 N.m (53 lb in).
  13. Install the electrical connector to the clutch coil bracket.
  14. Lower the vehicle.

Compressor Clutch Assembly Replacement

Tools Required

  1. J 25031-A Three Jaw Puller. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  2. J 39400-A Halogen Leak Detector. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  3. J 45267 Clutch Holding Tool. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  4. J 45504 Clutch Pulley Installer. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  5. SA9149AC-8 Snap Ring Pliers. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Remove the compressor. Refer to «Compressor Replacement (L61)»(ref-188838-S09725816932005090200000) or «Compressor Replacement (L66)»(ref-188838-S22502293252005090200000) .
  2. Use J 45267 to hold the disk and hub assembly. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) . Remove the clutch nut and the disk and hub assembly.
  3. Remove the spacer.
  4. Use SA9149AC-8 to remove the pulley snap ring. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  5. Use J 25031-A to remove the A/C clutch pulley. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  6. Remove the thermal switch bolt and the hold-down bracket.
  7. Lift out the thermal switch while lightly twisting and pulling up on the sensor.
  8. Use SA9149AC-8 to remove the field coil snap ring. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  9. Remove the A/C clutch field coil.
  1. Clean the mounting surfaces on the A/C clutch field coil and pulley.
  2. Install the A/C clutch field coil.
  3. Use SA9149AC-8 to install the field coil snap ring with the bevel side out. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  4. Clean the thermal switch pocket if necessary.
  5. Apply thermal switch sealant, approximately the size of a pea, into the switch pocket.
  6. Install the thermal switch by pushing the switch into place and wetting out the sealant, while holding the switch in place. Wipe away any excess sealant.
  7. Install the thermal switch hold-down bracket and bolt. Tighten: Tighten the bolt to 6 N.m (53 lb in).
  8. Use J 45504 to align the clutch bearing/pulley assembly over the hub. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) . Gently tap on the assembly to install.
  9. Use SA9149AC-8 to install the pulley snap ring with the bevel side out. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  10. Install the spacer.
  11. Install the drive plate and nut. Use the old nut to evaluate the clearances.
  12. Using a feeler gauge, measure the clearance between the pulley and the drive plate. Measure: The clearance should be 0.35-0.75 mm (0.014-0.030 in).
  13. If necessary, adjust the clearance by adding or removing clutch hub spacers.
  14. Once the correct air gap is obtained, install a new clutch nut. Use J 45267 to hold the disk and hub assembly while tightening. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) . Tighten: Tighten the nut to 19 N.m (14 lb ft).
  15. Install the compressor. Refer to «Compressor Replacement (L61)»(ref-188838-S09725816932005090200000) or «Compressor Replacement (L66)»(ref-188838-S22502293252005090200000) .
  16. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  17. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  3. Remove pressure relief valve from compressor hose.
  1. Lubricate the pressure relief valve O-ring with new R-12 mineral compressor oil. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  2. Install the pressure relief valve to the compressor hose. Tighten: Tighten the pressure relief valve to 10 N.m (89 in ft).
  3. Lower the vehicle.
  4. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  5. Test the affected A/C joint for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  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 For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). For banjo style fittings remove the bolt retaining the banjo type fitting.
  2. Remove the O-ring seal from the A/C refrigerant component.
  3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.
  4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
  5. Cap or tape the A/C refrigerant components.
  6. Discard the O-ring seal.
  1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
  2. Remove the cap or tape from the A/C refrigerant components.
  3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.
  4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
  5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
  6. The O-ring seal must be fully seated.
  7. Assemble the A/C components. Refer to the appropriate repair procedure. For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  3. Remove the compressor hose bolt from the compressor.
  4. Remove the compressor hose from the compressor.
  5. Remove and discard the O-rings from the compressor. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  6. Install a protective cap to the compressor to prevent contamination and desiccant saturation.
  7. Lower the vehicle.
  8. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-188773-S08477934822005090200000) in Lighting Systems.
  9. Remove the compressor hose nut from the condenser.
  10. Remove the compressor hose from the condenser.
  11. Install a protective cap to the condenser to prevent contamination and desiccant saturation.
  12. Remove the compressor hose nut from the evaporator outlet hose.
  13. Remove the compressor hose from the evaporator outlet hose.
  14. Install a protective cap to the evaporator outlet hose to prevent contamination and desiccant saturation.
  15. Remove the compressor hose from the vehicle.
  16. Remove and discard the sealing washers from the suction hose and the condenser ends of the compressor hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  1. Install new seal washers to the evaporator outlet hose and the condenser ends of the compressor hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  2. Position the compressor hose in the vehicle.
  3. Remove the protective cap from the evaporator outlet hose.
  4. Install the compressor hose to the evaporator outlet hose.
  5. Install the compressor hose nut to the evaporator outlet hose. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  6. Remove the protective cap from the condenser.
  7. Install the compressor hose to the condenser.
  8. Install the compressor hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  9. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  10. Remove the protective cap from the compressor.
  11. Install new O-rings to the compressor. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  12. Install the compressor hose to the compressor.
  13. Install the compressor hose bolt to the compressor. Tighten: Tighten the bolt to 27 N.m (20 lb ft).
  14. Lower the vehicle.
  15. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  16. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  17. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-188773-S08477934822005090200000) in Lighting Systems.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-188773-S08477934822005090200000) in Lighting Systems.
  3. Remove the compressor hose nut from the battery box.
  4. Remove the compressor hose from the battery box.
  5. Remove the compressor hose nut from the TXV.
  6. Remove the compressor hose from the TXV.
  7. Install a protective cap to the TXV to prevent contamination and desiccant saturation.
  8. Remove the compressor hose nut from the condenser.
  9. Remove the compressor hose nut from the condenser.
  10. Install a protective cap to condenser to prevent contamination and desiccant saturation.
  11. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  12. Remove the compressor hose bolt from the compressor.
  13. Remove the compressor hose from the compressor.
  14. Remove and discard the O-rings from the compressor. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  15. Install a protective cap to the compressor to prevent contamination and desiccant saturation.
  16. Remove the compressor hose from the vehicle.
  17. Remove and discard the sealing washers from the TXV and the condenser ends of the compressor hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  1. Install new seal washers to the TXV and the condenser ends of the compressor hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  2. Position the compressor hose in the vehicle.
  3. Remove the protective cap from the compressor.
  4. Install new O-rings to the compressor. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  5. Install the compressor hose to the compressor.
  6. Install the compressor hose bolt to the compressor. Tighten: Tighten the bolt to 27 N.m (20 lb ft).
  7. Lower vehicle.
  8. Remove the protective cap from the TXV.
  9. Install the compressor hose to the TXV.
  10. Install the compressor hose nut to the TXV. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  11. Remove the protective cap from the condenser.
  12. Install the compressor hose to the condenser.
  13. Install the compressor hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  14. Install the compressor hose to the battery box.
  15. Install the compressor hose nut to the battery box. Tighten: Tighten the nut to 8 N.m (71 lb in).
  16. Install left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-188773-S08477934822005090200000) in Lighting Systems.
  17. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  18. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-188773-S08477934822005090200000) in Lighting Systems.
  3. Remove the surge tank. Refer to «Surge Tank Replacement»(ref-188798-S22458457372005090200000) in Engine Cooling.
  4. Remove the washer bottle. Refer to «Washer Pump/Reservoir Replacement»(ref-188800-S40876899512005090200000) in Wiper/Washer Systems.
  5. Remove the battery. Refer to «Battery Replacement»(ref-188769-S31052717452005090200000) in Engine Electrical.
  6. Remove the battery box bolts from the battery box.
  7. Disconnect the negative battery cable from the wheelhouse.
  8. Remove the nut retaining the liquid line to the strut tower.
  9. Disconnect the harness and vent hose retainers from the liquid line.
  10. Remove the evaporator outlet hose nut from the TXV.
  11. Remove the evaporator outlet hose from the TXV.
  12. Remove the liquid line nut from the TXV.
  13. Remove the liquid line from the TXV.
  14. Remove the liquid line nut from the receiver dehydrator.
  15. Remove the liquid line from the receiver dehydrator.
  16. Position the battery box inboard to allow for routing of the liquid line.
  17. Route the liquid line above the battery box and the ground lug.
  18. Lift the rear portion of the liquid line upward and remove the liquid line from the vehicle.
  19. Remove and discard the sealing washer from the liquid line. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  20. Install protective caps to the receiver dehydrator and the TXV to prevent contamination and desiccant saturation.
  1. Remove the protective caps from the receiver dehydrator and the liquid line.
  2. Install the new sealing washer to the receiver dehydrator. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  3. Route the receiver dehydrator end of the liquid line into position.
  4. Install the liquid line to the receiver dehydrator.
  5. Install the liquid line nut to the receiver dehydrator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  6. Remove the protective cap from the TXV and the liquid line.
  7. Install a new sealing washer to the liquid line at the TXV.
  8. Install the liquid line to the TXV.
  9. Install the liquid line nut to the TXV. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  10. Install the evaporator outlet hose to the TXV.
  11. Install the evaporator outlet hose nut to the TXV. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  12. Route the liquid line below the battery box and the ground lug.
  13. Connect the negative battery cable to the wheelhouse.
  14. Install the battery box bolts to the battery box. Tighten: Tighten the nut to 15 N.m (11 lb ft).
  15. Install the battery. Refer to «Battery Replacement»(ref-188769-S31052717452005090200000) in Engine Electrical.
  16. Install the liquid line to the strut tower.
  17. Install the liquid line nut to the strut tower. Tighten: Tighten the nut to 5 N.m (44 lb in).
  18. Connect the harness and vent hose retainers to the liquid line.
  19. Install the surge tank. Refer to «Surge Tank Replacement»(ref-188798-S22458457372005090200000) in Engine Cooling.
  20. Install the washer bottle. Refer to «Washer Pump/Reservoir Replacement»(ref-188800-S40876899512005090200000) in Wiper/Washer Systems.
  21. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-188773-S08477934822005090200000) in Lighting Systems.
  22. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  23. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-188773-S08477934822005090200000) in Lighting Systems.
  3. Remove the air cleaner duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  4. Remove the surge tank. Refer to «Surge Tank Replacement»(ref-188798-S22458457372005090200000) in Engine Cooling.
  5. Remove the battery tray. Refer to «Battery Tray Replacement (L61)»(ref-188769-S41969954022005090200000) or «Battery Tray Replacement (L66)»(ref-188769-S02099368162005090200000) in Engine Electrical.
  6. Loosen the ABS brake modulator assembly nuts from the modulator bracket, if equipped.
  7. Carefully reposition the ABS brake modulator to allow for liquid line removal, if equipped.
  8. Remove the liquid line nut from the TXV.
  9. Remove the liquid line from the TXV.
  10. Remove the nut retaining the liquid line to the strut tower.
  11. Remove the nut retaining the liquid line to the strut tower.
  12. Remove the liquid line nut from the receiver dehydrator.
  13. Remove the liquid line from the receiver dehydrator.
  14. Lift the rear portion of the liquid line upward and remove the liquid line from the vehicle.
  15. Remove and discard the sealing washer from the liquid line. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  16. Install protective caps to the receiver dehydrator and the TXV to prevent contamination and desiccant saturation.
  1. Remove the protective caps from the receiver dehydrator and the liquid line.
  2. Install the new sealing washer to the receiver dehydrator. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  3. Route the receiver dehydrator end of the liquid line into position.
  4. Install the liquid line to the receiver dehydrator.
  5. Install the liquid line nut to the receiver dehydrator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  6. Carefully reposition the ABS brake modulator assembly to the modulator bracket, if equipped.
  7. Tighten the brake modulator assembly nuts to the ABS modulator bracket, if equipped. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  8. Remove the protective cap from the TXV and the liquid line.
  9. Install a new sealing washer to the liquid line at the TXV.
  10. Install the liquid line to the TXV.
  11. Install the liquid line nut to the TXV. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  12. Install the liquid line to the strut tower.
  13. Install the liquid line nut to the strut tower. Tighten: Tighten the nut to 10 N.m (89 lb in).
  14. Install the battery tray. Refer to «Battery Tray Replacement (L61)»(ref-188769-S41969954022005090200000) or «Battery Tray Replacement (L66)»(ref-188769-S02099368162005090200000) in Engine Electrical.
  15. Install the surge tank. Refer to «Surge Tank Replacement»(ref-188798-S22458457372005090200000) in Engine Cooling.
  16. Install the air cleaner duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  17. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-188773-S08477934822005090200000) in Lighting Systems.
  18. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  19. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Remove the air cleaner outlet duct from the vehicle. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  3. Remove the compressor hose nut from the evaporator outlet hose.
  4. Separate the compressor hose from the evaporator outlet hose.
  5. Remove and discard the seal washer from the compressor hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  6. Install a protective cap to the compressor hose to prevent contamination and desiccant saturation.
  7. Remove the evaporator outlet hose bolt from the air cleaner outlet duct bracket.
  8. Remove the evaporator outlet hose nut from the cowl.
  9. Remove the evaporator outlet hose nut from the TXV.
  10. Remove the evaporator outlet hose from the TXV.
  11. Install a protective cap to the TXV to prevent contamination and desiccant saturation.
  12. Remove and discard the seal washer from the evaporator outlet hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  1. Install a new seal washer to the evaporator outlet hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  2. Remove the protective cap from the TXV.
  3. Install the evaporator outlet hose to the TXV.
  4. Install the evaporator outlet hose nut to the TXV. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  5. Install the evaporator outlet hose nut to the cowl. Tighten: Tighten the nut to 8 N.m (71 lb in).
  6. Install the evaporator outlet hose bolt to the air cleaner outlet duct bracket. Tighten: Tighten the bolt to 7 N.m (62 lb in).
  7. Remove the protective cap from the compressor hose.
  8. Install a new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  9. Install the compressor hose to the evaporator outlet hose.
  10. Install the compressor hose nut to the evaporator outlet hose. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  11. Install the air cleaner outlet duct to the vehicle. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  12. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  13. Test the affected A/C fittings for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .

Service Port Valve Core Replacement

Tools Required

  1. J 39400-A Halogen Leak Detector. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  2. J 46246 Valve Core Removal Tool. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Use J 46246 or equivalent to remove the valve core. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Use J 46246 or equivalent to install and tighten the valve core. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  2. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  3. Test the affected A/C fittings for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Remove the left headlamp assembly. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-188773-S08477934822005090200000) in Lighting Systems.
  3. Remove the receiver dehydrator nut from the condenser.
  4. Remove the receiver dehydrator nut from the liquid line.
  5. Remove the receiver dehydrator bracket bolt from the vehicle.
  6. Remove the receiver dehydrator from the vehicle.
  7. Install protective caps to the condenser, the liquid line, and the receiver dehydrator to prevent contamination and desiccant saturation.
  1. Remove the protective caps from the condenser, the liquid line, and the receiver dehydrator.
  2. Add the specified amount of PAG oil to the receiver dehydrator. Refer to «Refrigerant System Capacities»(ref-188838-S39986627642005090200000) .
  3. Install new seal washers to the receiver dehydrator. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  4. Install the receiver dehydrator to the vehicle.
  5. Install the receiver dehydrator nut to the liquid line. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  6. Install the receiver dehydrator nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  7. Position the receiver dehydrator in the vehicle.
  8. Install the receiver dehydrator nut to the vehicle. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  9. Install left head lamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-188773-S08477934822005090200000) in Lighting Systems.
  10. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  11. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Remove the evaporator outlet hose nut from the TXV.
  3. Remove the evaporator outlet hose from the TXV.
  4. Install a protective cap to the evaporator outlet hose to prevent contamination and desiccant saturation.
  5. Remove the liquid line nut from the TXV.
  6. Remove the liquid line from the TXV.
  7. Install a protective cap to the liquid line to prevent contamination and desiccant saturation.
  8. Disconnect the refrigerant low temperature sensor from the engine harness.
  9. Remove the TXV bolts from the backing plate.
  10. Remove the TXV and the backing plate from the vehicle.
  11. Remove and discard the O-rings from the evaporator pipes. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  12. Install a protective cap to the evaporator pipes to prevent contamination and desiccant saturation.
  1. Remove the protective caps from the evaporator pipe and ensure the seal areas are clean, dry and lint free.
  2. Install new O-rings to the evaporator pipes. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  3. Remove the protective caps from the TXV.
  4. Install the TXV and the backing plate to the evaporator pipes.
  5. Install the TXV bolts to the backing plate. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  6. Remove the protective cap from the liquid line.
  7. Install a new seal washer to the liquid line. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  8. Install the liquid line to the TXV.
  9. Install the liquid line nut to the TXV. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  10. Remove the protective cap from the evaporator outlet hose.
  11. Install a new seal washer to the evaporator outlet hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  12. Install the evaporator outlet hose to the TXV.
  13. Install the evaporator outlet hose nut to the TXV. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  14. Connect the refrigerant low temperature sensor to the engine harness.
  15. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  16. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .

The second design can be identified by the attachment method of the evaporator outlet hose and the liquid line to the Thermal Expansion Valve (TXV). They are retained to the TXV as a pair using a single nut.

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Remove the evaporator outlet hose and liquid line retainer plate nut from the TXV.
  3. Remove the evaporator outlet hose and liquid line from the TXV.
  4. Remove and discard the sealing washers from the evaporator outlet hose and liquid line.
  5. Install protective caps to the evaporator outlet hose and the liquid line to prevent contamination and desiccant saturation.
  6. Remove the TXV bolts from the backing plate.
  7. Remove the TXV and the backing plate from the vehicle.
  8. Remove and discard the O-rings from the evaporator pipes. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  9. Install a protective cap to the evaporator pipes to prevent contamination and desiccant saturation.
  1. Remove the protective caps from the evaporator pipe and ensure the seal areas are clean, dry and lint free.
  2. Install new O-rings to the evaporator pipes. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  3. Remove the protective caps from the TXV.
  4. Install the TXV and the backing plate to the evaporator pipes.
  5. Install the TXV bolts to the backing plate. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  6. Remove the protective caps from the liquid line and the evaporator outlet hose
  7. Install new seal washers to the liquid line and the evaporator outlet hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  8. Install the liquid line and the evaporator outlet hose to the TXV.
  9. Install the liquid line and evaporator outlet hose retainer plate nut to the TXV. Tighten: Tighten the nut to 20 N.m (15 lb ft).
  10. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  11. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) .
  2. Disconnect the electrical connector from the refrigerant pressure sensor.
  3. Remove the refrigerant pressure sensor from the compressor hose.
  1. Lubricate the refrigerant pressure sensor O-ring with mineral oil. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  2. Hand start the refrigerant pressure sensor to the compressor hose, taking care not to pinch the O-ring and tighten. Tighten: Tighten the pressure sensor to 10 N.m (89 lb in).
  3. Install the electrical connector to the refrigerant pressure sensor.
  4. Lower the vehicle.
  1. Disconnect the thermal expansion valve (TXV) temperature sensor from the engine harness.
  2. Remove the temperature sensor from the TXV.
  1. Fill the temperature sensor housing in the TXV with the thermal grease included with the service kit.
  2. Install the temperature sensor and wipe away the excess grease.
  3. Install the temperature sensor bolt. Tighten: Tighten the bolt to 5 N.m (44 lb in).
  4. Connect the temperature sensor to the engine harness.

The second design can be identified by the location of the temperature sensor. The temperature sensor is retained with a screw to the evaporator pipe.

  1. Disconnect the thermal expansion valve (TXV) temperature sensor from the engine harness.
  2. Remove the temperature sensor screw from the evaporator pipe.
  3. Remove the temperature sensor from the evaporator pipe.
  1. Fill the temperature sensor housing in the TXV with the thermal grease included with the service kit.
  2. Install the temperature sensor and wipe away the excess grease.
  3. Install the temperature sensor screw. Tighten: Tighten the screw to 8.5 N.m (75 lb in).
  4. Connect the temperature sensor to the engine harness.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  2. Remove the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) .
  3. For L61 vehicles, remove the battery box air duct.
  4. Remove the condenser radiator fan module (CRFM) closeout panel.
  5. Remove receiver dehydrator from the condenser.
  6. Install a protective cap to the receiver dehydrator to prevent contamination and desiccant saturation.
  7. Remove the compressor hose from the condenser.
  8. Install a protective cap to the compressor hose to prevent contamination and desiccant saturation.
  9. Lift the condenser while holding the upper retention tabs forward.
  10. Remove the condenser from the vehicle.
  1. Add the specified amount of PAG oil to the condenser. Refer to «Refrigerant System Capacities»(ref-188838-S39986627642005090200000) .
  2. Inspect the radiator to condenser seals for the proper position.
  3. Install the condenser by guiding the tabs into the retention clips on the radiator. Press down to engage the retention clips.
  4. Remove the protective cap from the compressor hose.
  5. Install a new sealing washer to the compressor hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  6. Install the compressor hose to the condenser.
  7. Install compressor hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  8. Install a new seal washer to the receiver dehydrator. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  9. Install the receiver dehydrator to the condenser.
  10. Install the receiver dehydrator nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  11. Install the CRFM closeout panel.
  12. For L61 vehicles, install the battery box air duct.
  13. Install the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) .
  14. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  15. Use J 39400-A to test the affected A/C joints leaks. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Remove the evaporator core. Refer to «Evaporator Core Replacement (First Design)»(ref-188838-S31923073382005090200000) .
  2. Remove the air inlet assembly. Refer to «Air Inlet Assembly Replacement»(ref-188838-S20262657182005090200000) .
  3. Remove the HVAC module wire harness from the blower case assembly.
  4. Remove the blower motor screws from the blower case assembly.
  5. Remove the blower motor from the blower case assembly.
  6. Remove the blower motor resistor screws from the blower case assembly.
  7. Remove the blower motor resistor from the blower case assembly.
  1. Install the blower motor resistor to the blower case assembly.
  2. Install the blower motor resistor screws to the blower case assembly. Tighten: Tighten the screws to 1 N.m (9 lb in).
  3. Install the blower motor to the blower case assembly.
  4. Install the blower motor screws to the blower case assembly. Tighten: Tighten the screws to 1 N.m (9 lb in).
  5. Install the HVAC module wire harness from the blower case assembly.
  6. Install the air inlet assembly. Refer to «Air Inlet Assembly Replacement»(ref-188838-S20262657182005090200000) .
  7. Install the evaporator core. Refer to «Evaporator Core Replacement (First Design)»(ref-188838-S31923073382005090200000) .
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-188838-S27067289512005090200000) .
  2. Remove the heater duct screws from the heater core cover.
  3. Remove the heater duct from the heater core cover.
  4. Remove the panel actuator screws from the evaporator case assembly.
  5. Remove the panel actuator from the evaporator case assembly.
  6. Remove the floor actuator screws from the evaporator case assembly.
  7. Remove the floor actuator from the evaporator case assembly.
  8. Remove the defrost actuator screws from the evaporator case assembly.
  9. Remove the defrost actuator from the evaporator case assembly.
  10. Remove the heater core cover screws from the evaporator case assembly.
  11. Remove the heater core cover from the evaporator case assembly.
  12. Remove the heater core pipe cover screw.
  13. Remove the heater core pipe cover.
  14. Remove the heater core pipe seal.
  15. Grasp the heater core at the end tanks and remove. Spraying perimeter of heater core seal with a soap and water mixture will ease removal.
  16. Remove the evaporator case assembly screws from the blower case assembly.
  17. Remove the evaporator case assembly from the blower case assembly.
  1. Install evaporator case assembly to the blower case assembly.
  2. Install evaporator case assembly screws to the blower case assembly. Tighten: Tighten the screws to 1 N.m (9 lb in).
  3. Install heater core. Spraying perimeter of heater core seal with a soap and water mixture will ease installation.
  4. Install heater core pipe seal.
  5. Install heater core pipe cover.
  6. Install heater core pipe cover screw. Tighten: Tighten the screw to 1 N.m (9 lb in).
  7. Install heater core cover.
  8. Install heater core cover screws. Tighten: Tighten the screws to 1 N.m (9 lb in).
  9. Install the floor actuator to the evaporator case assembly.
  10. Install the floor actuator screws to the evaporator case assembly. Tighten: Tighten the screws to 1 N.m (9 lb in).
  11. Install the defrost actuator to the evaporator case assembly.
  12. Install the defrost actuator screws to the evaporator case assembly. Tighten: Tighten the screws to 1 N.m (9 lb in).
  13. Install the panel actuator to the evaporator case assembly.
  14. Install the panel actuator screws to the evaporator case assembly. Tighten: Tighten the screws to 1 N.m (9 lb in).
  15. Install the heater duct.
  16. Install the heater duct screws. Tighten: Tighten the screws to 1 N.m (9 lb in).
  17. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-188838-S27067289512005090200000) .

HVAC Module Assembly Replacement

Tools Required

  1. J 39400-A Halogen Leak Detector. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  2. SA9111E Hose Clamp Pliers. See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  1. Disable the frontal and curtain air bags. Refer to «SIR Disabling and Enabling Zone 2»(ref-188787-S19700968952005090200000) , «SIR Disabling and Enabling Zone 3»(ref-188787-S29990789502005090200000) , «SIR Disabling and Enabling Zone 5»(ref-188787-S31966200632005090200000) , and «SIR Disabling and Enabling Zone 6»(ref-188787-S17872444182005090200000) in SIR.
  2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  3. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  4. Remove the evaporator outlet hose nut from the TXV.
  5. Remove the evaporator outlet hose from the TXV.
  6. Remove and discard the sealing washer from the evaporator outlet hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  7. Install a protective cap to the evaporator outlet hose to prevent contamination and desiccant saturation.
  8. Remove the liquid line nut from the TXV.
  9. Remove the liquid line from the TXV.
  10. Remove and discard the sealing washer from the liquid line. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  11. Install a protective cap to the liquid line to prevent contamination and desiccant saturation.
  12. Disconnect the TXV low temperature sensor connector from the engine harness.
  13. Reposition the heater outlet hose clamp at the heater core using SA9111E . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  14. Remove the heater outlet hose from the heater core.
  15. Reposition the heater inlet hose clamp at the heater core using SA9111E . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  16. Remove the heater inlet hose at the heater core.
  17. Plug the heater core and the evaporator core with clean towels to prevent spillage when the HVAC module is removed.
  18. Remove the HVAC module seal nuts from the front of dash.
  19. Remove the instrument panel (I/P) retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-188790-S37992479252005090200000) in Instrument Panel, Gages, and Console.
  20. Remove the shift control bracket. Refer to «Shift Control Replacement»(ref-188822-S10608395402005090200000) in Manual Transmission - Getrag 5 or «Shift Control Replacement»(ref-188804-S13655679252005090200000) in Automatic Transmission - VT25-E.
  21. Remove the center floor air outlet duct by sliding the duct forward then up at the rear.
  22. Remove the center I/P air outlet duct retainers from the cross car beam.
  23. Remove the center I/P air outlet duct from the cross car beam.
  24. Disconnect the blower motor electrical connector from the I/P wire harness.
  25. Disconnect the blower motor resistor electrical connector from the I/P wire harness.
  26. Disconnect the HVAC module electrical connector from the I/P wire harness.
  27. Remove the defroster duct retainer from the cross car beam.
  28. Remove the defroster duct nuts from the HVAC module.
  29. Remove the defroster duct from the HVAC module.
  30. Disconnect the I/P wire harness clips from the HVAC module.
  31. Remove the metal bracket nut from the cross car beam.
  32. Remove the metal bracket nuts from the HVAC module.
  33. Remove the metal bracket from the HVAC module.
  34. Remove the HVAC module bolts from the right side of the cross car beam.
  35. Remove the HVAC module nut from the center of the cross car beam.
  36. Remove HVAC module bolt from the left side of the cross car beam.
  37. Remove the HVAC module from the vehicle.
  1. Inspect the front of dash seal for proper alignment.
  2. Inspect the seal mating surfaces to ensure there are no obstructions.
  3. Loose hang the HVAC module from the cross car beam.
  4. Install the metal bracket to the left side of the HVAC module.
  5. Install the metal bracket bolts to the left side of the HVAC module. Tighten: Tighten the bolts to 2 N.m (18 lb in).
  6. Install the HVAC module seal nuts to the front of dash. Draw the HVAC module to the front of dash evenly by alternating between the seal nuts. Tighten: Tighten the nuts to 8 N.m (71 lb in).
  7. Install the HVAC module bolts to the right side of the cross car beam.
  8. Push up on the right side of the HVAC module while tightening the HVAC module bolts to the cross car beam. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  9. Install the HVAC module bolt to the left side of the cross car beam. Tighten: Tighten the bolt to 8 N.m (71 lb in).
  10. Install the HVAC module nuts to the left side and center of the cross car beam. Tighten: Tighten the nuts to 8 N.m (71 lb in).
  11. Install the defroster duct to the HVAC module.
  12. Install the defroster duct nuts to the HVAC module. Tighten: Tighten the nuts to 2.5 N.m (22 lb in).
  13. Install the defroster duct retainer to the cross car beam.
  14. Connect the I/P wire harness clips to the HVAC module.
  15. Connect the blower motor electrical connector to the I/P wire harness.
  16. Connect the blower motor resistor electrical connector to the I/P wire harness.
  17. Connect the HVAC module electrical connector to the I/P wire harness.
  18. Install the center I/P duct to the cross car beam.
  19. Install the center I/P duct retainers to the cross car beam.
  20. Install the center floor air outlet by sliding forward onto the front floor air outlet then down and rearward over the rear floor air outlet.
  21. Install the shift control bracket. Refer to «Shift Control Replacement»(ref-188822-S10608395402005090200000) in Manual Transmission - Getrag 5 or «Shift Control Replacement»(ref-188804-S13655679252005090200000) in Automatic Transmission - VT25-E.
  22. Install the I/P retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-188790-S37992479252005090200000) in Instrument Panel, Gages, and Console.
  23. Install the heater inlet hose to the heater core.
  24. Install the heater inlet hose clamp to the heater core using SA9111E . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  25. Install the heater outlet hose to heater core outlet.
  26. Install the heater outlet hose clamp to the heater core using SA9111E . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .
  27. Ensure the mating surfaces are clean and free of debris, and install a new seal washer to the liquid line. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  28. Install the liquid line to the TXV.
  29. Install the liquid line nut to the TXV. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  30. Ensure the mating surfaces are clean and free of debris, and install a new seal washer to the evaporator outlet hose. Refer to «Sealing Washer Replacement»(ref-188838-S36139912392005090200000) .
  31. Install the evaporator outlet hose to the TXV.
  32. Install the evaporator outlet hose nut to the TXV. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  33. Enable the frontal and curtain air bags. Refer to «SIR Disabling and Enabling Zone 2»(ref-188787-S19700968952005090200000) , «SIR Disabling and Enabling Zone 3»(ref-188787-S29990789502005090200000) , «SIR Disabling and Enabling Zone 5»(ref-188787-S31966200632005090200000) , and «SIR Disabling and Enabling Zone 6»(ref-188787-S17872444182005090200000) in SIR.
  34. Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  35. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) .
  36. Test the affected A/C joints for leaks using J 39400-A . See «Special Tools and Equipment»(ref-188838-S21322641972005090200000) .

The first design can be identified by the attachment method of the evaporator outlet hose and the liquid line to the thermal expansion valve (TXV). They are retained to the TXV independently using nuts.

  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-188838-S27067289512005090200000) .
  2. Remove the evaporator case assembly. Refer to «Air Conditioning (A/C) Evaporator Case Assembly Replacement»(ref-188838-S02521069962005090200000) .
  3. Remove the TXV bolts from the backing plate.
  4. Remove the TXV and the backing plate from the evaporator pipes.
  5. Remove the O-rings from evaporator pipes. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  6. Install protective caps to the evaporator pipes to prevent system contamination.
  7. Remove the HVAC module front of dash seal.
  8. Remove the evaporator pipe cover screw from the blower case assembly.
  9. Remove the evaporator pipe cover from the blower case assembly.
  10. Remove the evaporator core from the blower case assembly. Spraying the perimeter of the evaporator core seal with a soap and water mixture will ease removal.
  1. Add the proper of polyalkylene glycol (PAG) oil to the evaporator core. Refer to «Refrigerant System Capacities»(ref-188838-S39986627642005090200000) .
  2. Inspect the seal around the evaporator core. Make sure the seal is in correct position and retained properly.
  3. Spray the seal with a soap and water mixture to ease the installation of evaporator core.
  4. Install the evaporator core to the blower case assembly.
  5. Install the evaporator pipe cover.
  6. Install the evaporator pipe cover screw. Tighten: Tighten the screw to 1 N.m (9 lb in).
  7. Install the HVAC module front of dash seal.
  8. Remove the protective caps from the evaporator pipes and ensure the seal areas are clean, dry and lint-free.
  9. Install new O-rings to the evaporator pipes. Refer to «O-Ring Replacement»(ref-188838-S31080200462005090200000) .
  10. Instal the TXV and the backing plate to the evaporator pipes.
  11. Install the TXV screws to the backing plate. Tighten: Tighten the screws to 9 N.m (80 lb in).
  12. Install the evaporator case assembly. Refer to «Air Conditioning (A/C) Evaporator Case Assembly Replacement»(ref-188838-S02521069962005090200000) .
  13. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-188838-S27067289512005090200000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  2. Remove the heater inlet hose clamp from the heater core.
  3. Remove the heater inlet hose from the heater core.
  4. Remove the heater inlet hose clamp from the engine.
  5. Remove the heater inlet hose from the engine.
  1. Install the heater inlet hose to the engine.
  2. Install the heater inlet hose clamp to the engine.
  3. Install the heater inlet hose to the heater core.
  4. Install the heater inlet hose clamp to the heater core.
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  2. Remove the air cleaner outlet duct from the vehicle. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  3. Remove the heater inlet hose clamp from the heater core.
  4. Remove the heater inlet hose from the heater core.
  5. Remove the heater inlet hose clamp from the elbow fitting.
  6. Remove the heater inlet hose from the elbow fitting.
  1. Install the heater inlet hose to the elbow fitting.
  2. Install the heater inlet hose clamp to the elbow fitting.
  3. Install the heater inlet hose to the heater core.
  4. Install the heater inlet hose clamp to the heater core.
  5. Install the air cleaner outlet duct to the vehicle. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  2. Remove the air cleaner outlet duct from the vehicle. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  3. Remove the heater inlet hose clamp from the elbow fitting.
  4. Remove the heater inlet hose from the elbow fitting.
  5. Remove the heater inlet hose clamp from the engine.
  6. Remove the heater inlet hose from the engine.
  1. Install the heater inlet hose to the engine.
  2. Install the heater inlet hose clamp to the engine.
  3. Install the heater inlet hose to the elbow fitting.
  4. Install the heater inlet hose clamp to the elbow fitting.
  5. Install the air cleaner outlet duct to the vehicle. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  2. Remove the heater outlet hose clamp from the heater core.
  3. Remove the heater outlet hose from the heater core.
  4. Remove the heater outlet hose clamp from the engine.
  5. Remove the heater outlet hose from the engine.
  1. Install the heater outlet hose to the engine port.
  2. Install the heater outlet hose clamp to the engine port.
  3. Install the heater outlet hose to the heater core.
  4. Install the heater outlet hose clamp to the heater core.
  5. Fill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  2. Remove the air cleaner outlet duct from the vehicle. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  3. Remove the heater outlet hose clamp from the heater core.
  4. Remove the heater outlet hose from the heater core.
  5. Remove the heater outlet hose clamp from the "T" fitting.
  6. Remove the heater outlet hose from the "T" fitting.
  7. Remove the heater outlet hose clamp from the surge tank.
  8. Remove the heater outlet hose from the surge tank.
  1. Install the heater outlet hose to the surge tank.
  2. Install the heater outlet hose clamp to the surge tank.
  3. Install the heater outlet hose to the "T" fitting.
  4. Install the heater outlet hose clamp to the "T" fitting.
  5. Install the heater outlet hose to the heater core.
  6. Install the heater outlet hose clamp to the heater core.
  7. Install the air cleaner outlet duct to the vehicle. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  8. Fill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  2. Remove the air cleaner outlet duct from the vehicle. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  3. Remove the heater outlet hose clamp from the "T" fitting.
  4. Remove the heater outlet hose from the "T" fitting.
  5. Remove the heater outlet hose clamp from the engine.
  6. Remove the heater outlet hose from the engine.
  1. Install the heater outlet hose to the engine.
  2. Install the heater outlet hose clamp to the engine.
  3. Install the heater outlet hose to the "T" fitting.
  4. Install the heater outlet hose clamp to the "T" fitting.
  5. Install the air cleaner outlet duct to the vehicle. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
  6. Fill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  1. Remove the push pins from the air filter access panel.
  2. Lift the air filter access panel and disconnect the washer nozzle hose from the washer nozzle.
  3. Remove the air filter access panel.
  4. Remove the filter housing nuts from the body.
  5. Remove the filter housing from the body.
  1. Inspect the foam seal. If the seal is damaged, replace the seal using Kent Industries adhesive back foam tape P/N 46485 or equivalent.
  2. Install the filter housing to the body.
  3. Install the new seal nuts to the filter housing. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  4. Connect the washer nozzle hose to the washer nozzle.
  5. Install the air filter access panel.
  6. Install the push pins to the air filter access panel.
  1. Remove the push pins from the air filter access panel.
  2. Remove the air filter access panel.
  3. Remove the air filter from the housing.
  1. Install the air filter into the housing.
  2. Install the air filter access panel.
  3. Install the air filter access panel push pins.
  1. Remove the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-188838-S27067289512005090200000) .
  2. Disconnect the electrical connector from the recirculation actuator.
  3. Unclip the wire harness from the HVAC module end bracket.
  4. Remove the end bracket screws from the air inlet assembly.
  5. Remove the end bracket nuts from the blower case assembly.
  6. Remove the end bracket from the blower case assembly.
  7. Remove the recirculation actuator screws.
  8. Remove the recirculation actuator.
  9. Remove the air inlet assembly screws.
  10. Remove the air inlet assembly.
  1. Install the air inlet assembly.
  2. Install the air inlet assembly screws. Tighten: Tighten the screws to 1 N.m (9 lb in).
  3. Install the recirculation actuator.
  4. Install the recirculation actuator screws. Tighten: Tighten the screws to 1 N.m (9 lb in).
  5. Route the HVAC module harness through the end bracket bottom hole and install the bracket.
  6. Install the end bracket screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
  7. Install the end bracket nuts. Tighten: Tighten the nuts to 2 N.m (18 lb in).
  8. Clip the wire harness to the end bracket.
  9. Install the electrical connector to the recirculation actuator.
  10. Install the HVAC module. Refer to «HVAC Module Assembly Replacement»(ref-188838-S27067289512005090200000) .
  1. Remove the right side insulator/closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-188790-S15931222192005090200000) in Instrument Panel, Gages and Console.
  2. Disconnect the electrical connector from the blower motor resistor.
  3. Remove the blower motor resistor screws from the HVAC module.
  4. Remove the blower motor resistor from the HVAC module.
  1. Install the blower motor resistor to the HVAC module.
  2. Install the blower motor resistor screws to the HVAC module. Tighten: Tighten the screws to 1 N.m (9 lb in).
  3. Connect the electrical connector to the blower motor resistor.
  4. Install the right side insulator/closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-188790-S15931222192005090200000) in Instrument Panel, Gages and Console.
  1. Remove the passenger side insulator/closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-188790-S15931222192005090200000) in Instrument Panel, Gages and Console.
  2. Disconnect the electrical connector from the blower motor.
  3. Remove the blower motor screws from the HVAC module.
  4. Remove the blower motor from the HVAC module.
  1. Install the blower motor to the HVAC module.
  2. Install the blower motor screws to the HVAC module. Tighten: Tighten the screws to 1 N.m (9 lb in).
  3. Connect the electrical connector to the blower motor.
  4. Install the passenger side insulator/closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-188790-S15931222192005090200000) in Instrument Panel, Gages and Console.
  1. Remove the right side insulator/closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-188790-S15931222192005090200000) in Instrument Panel, Gages and Console.
  2. Disconnect the electrical connector from the blower motor.
  3. Remove the blower motor screws from the HVAC module.
  4. Remove the blower motor from the HVAC module.
  5. Remove the blower motor impeller retention clip (1) from the blower motor shaft (2).
  6. Remove the blower motor impeller (1) from the blower motor (2).
  1. Install the blower motor impeller (1) to the blower motor (2).
  2. Install the blower motor impeller retention clip (1) to the blower motor shaft (2).
  3. Install the blower motor to the HVAC module.
  4. Install the blower motor screws to the HVAC module. Tighten: Tighten the screws to 1 N.m (9 lb in).
  5. Connect the electrical connector to the blower motor.
  6. Install the right side insulator/closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-188790-S15931222192005090200000) in Instrument Panel, Gages and Console.
  1. Remove the instrument panel (I/P) upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(ref-188790-S21858114352005090200000) in Instrument Panel, Gages, and Console.
  2. Depress the locking tabs on the outlet.
  3. Carefully slide the outlet out of the I/P trim and the surrounding outlet bezel.
  1. Install the outlet to the I/P trim panel. The outlet will snap into place.
  2. Install the I/P upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(ref-188790-S21858114352005090200000) in Instrument Panel, Gages, and Console.
  1. Remove the instrument panel upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(ref-188790-S21858114352005090200000) in Instrument Panel, Gages and Console.
  2. Remove the LH air outlet duct screws from the instrument panel retainer.
  3. Remove the LH air outlet duct from the instrument panel retainer.
  1. Inspect the seals and replace if damaged using Kent Industries adhesive backed foam tape P/N 46485 (or equivalent).
  2. Install the LH air outlet duct to the instrument panel retainer.
  3. Install the LH air outlet duct screws to the instrument panel retainer. Tighten: Tighten the screws to 1 N.m (9 lb in).
  4. Install the instrument panel upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(ref-188790-S21858114352005090200000) in Instrument Panel, Gages and Console.
  1. Remove the instrument panel upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(ref-188790-S21858114352005090200000) in Instrument Panel, Gages and Console.
  2. Remove the RH air outlet duct screws from the instrument panel retainer.
  3. Remove the RH air outlet duct from the instrument panel retainer.
  1. Inspect the seals and replace if damaged using Kent Industries adhesive backed foam tape P/N 46485 (or equivalent).
  2. Install the RH air outlet duct to the instrument panel retainer.
  3. Install the RH air outlet duct screws to the instrument panel retainer. Tighten: Tighten the screws to 1 N.m (9 lb in).
  4. Install the instrument panel upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(ref-188790-S21858114352005090200000) in Instrument Panel, Gages and Console.
  1. Remove the instrument panel retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-188790-S37992479252005090200000) in Instrument Panel, Gages, and Console.
  2. Remove the floor air outlet screws from the heater core cover.
  3. Remove the floor air outlet from the heater core cover.
  1. Install the floor air outlet to the heater core cover.
  2. Install the floor air outlet screws to the heater core cover. Tighten: Tighten the screws to 2 N.m (18 lb in).
  3. Install the instrument panel retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-188790-S37992479252005090200000) in Instrument Panel, Gages, and Console.
  1. Remove the shift control bracket. Refer to «Shift Control Replacement»(ref-188822-S10608395402005090200000) in Manual Transmission - Getrag 5 or «Shift Control Replacement»(ref-188804-S13655679252005090200000) in Automatic Transmission - VT25-E.
  2. Slide the center floor air outlet duct forward enough to clear the rear floor air outlet duct and then up and rearward to remove.
  1. Slide the center floor air outlet duct forward enough to clear rear floor air duct and then down and rearward to install.
  2. Install the shift control bracket. Refer to «Shift Control Replacement»(ref-188822-S10608395402005090200000) in Manual Transmission - Getrag 5 or «Shift Control Replacement»(ref-188804-S13655679252005090200000) in Automatic Transmission - VT25-E.
  1. Remove the front seats. Refer to «Seat Replacement - Front Bucket»(ref-188791-S36887021102005090200000) in Seats.
  2. Remove the floor console. Refer to «Console Replacement - Front Floor»(ref-188790-S14157393722005090200000) in Instrument Panel, Gages, and Console.
  3. Partially remove the floor carpet from the front footwells to the B-pillars.
  4. Remove the rear floor air outlet push pins from the floor pan.
  5. Remove the rear floor air outlet from the floor pan.
  1. Install the rear floor air outlet to the floor pan.
  2. Install the rear floor air outlet push pins to the floor pan.
  3. Install the floor carpet to the B-pillars and the front footwells.
  4. Install the floor console. Refer to «Console Replacement - Front Floor»(ref-188790-S14157393722005090200000) in Instrument Panel, Gages, and Console.
  5. Install the front seats. Refer to «Seat Replacement - Front Bucket»(ref-188791-S36887021102005090200000) in Seats.
  1. Remove the instrument panel retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-188790-S37992479252005090200000) in Instrument Panel, Gages and Console.
  2. Remove the center air outlet duct push pins from the cross car beam.
  3. Remove the center air outlet duct from the cross car beam.
  1. Inspect the seals and replace if damaged using Kent Industries adhesive backed foam tape P/N 46485 or equivalent.
  2. Install the center air outlet duct to the cross car beam.
  3. Install the center air outlet duct push pins to the cross car beam.
  4. Install the instrument panel retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-188790-S37992479252005090200000) in Instrument Panel, Gages and Console.
  1. Remove the instrument panel upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(ref-188790-S21858114352005090200000) in Instrument Panel, Gages, and Console.
  2. Remove the windshield defrost duct nuts from the HVAC module.
  3. Remove the windshield defrost duct from the HVAC module.
  1. Inspect the windshield defrost duct seals. If damaged, replace using Kent Industries adhesive back foam tape P/N 46485 or equivalent.
  2. Install the windshield defrost duct to the HVAC module.
  3. Install the windshield defrost duct nuts to the HVAC module. Tighten: Tighten the nuts to 2.5 N.m (22 lb in).
  4. Install the instrument panel upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(ref-188790-S21858114352005090200000) in Instrument Panel, Gages, and Console.
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
  2. Remove the heater outlet hose clamp from the heater core.
  3. Remove the heater outlet hose from the heater core.
  4. Remove the heater inlet hose clamp from the heater core.
  5. Remove the heater inlet hose from the heater core.
  6. Remove the instrument panel retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-188790-S37992479252005090200000) in Instrument Panel, Gages, and Console.
  7. Remove the shift control bracket. Refer to Transmission Shift Control Bracket Replacement in Manual Transmission - Getrag 5 or «Shift Control Replacement»(ref-188804-S13655679252005090200000) in Automatic Transmission - VT25-E.
  8. Remove the heater duct screws.
  9. Remove the heater duct.
  10. Remove the heater core cover screws.
  11. Remove the heater core cover.
  12. Remove the heater core pipe cover screw.
  13. Remove the heater core pipe cover.
  14. Remove the heater core pipe foam seal.
  15. Grasp the heater core at end tanks and remove heater core. Spray the perimeter of the heater core seal and the heater core pipes at the front of dash with a soap and water mixture to ease removal.
  1. Install the heater core. Spray the perimeter of the heater core seal and the heater core pipes at the front of dash with a soap and water mixture to ease installation.
  2. Install the heater core pipe seal.
  3. Install the heater core pipe cover.
  4. Install the heater core pipe cover screw. Tighten: Tighten the screw to 1 N.m (9 lb in).
  5. Spray the front of dash seal at the drain tube opening to aid in heater core cover installation.
  6. Install the heater core cover.
  7. Install the heater core cover screws. Tighten: Tighten the screw to 1 N.m (9 lb in).
  8. Install the heater duct.
  9. Install the heater duct screws. Tighten: Tighten the screw to 1 N.m (9 lb in).
  10. Install the instrument panel retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(ref-188790-S37992479252005090200000) in Instrument Panel, Gages, and Console.
  11. Install the shift control bracket. Refer to Transmission Shift Control Bracket Replacement in Manual Transmission - Getrag 5 or «Shift Control Replacement»(ref-188804-S13655679252005090200000) in Automatic Transmission - VT25-E.
  12. Install the heater inlet hose to the heater core.
  13. Install the heater inlet hose clamp to the heater core.
  14. Install the heater outlet hose to the heater core.
  15. Install the heater outlet hose clamp to the heater core.
  16. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.

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