See: Heating and Air Conditioning\Service Precautions
- ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
- REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.
- Remove the HVAC housing from the vehicle. See: Heating and Air Conditioning\Housing Assembly HVAC\Service and Repair
- Remove the foam gasket surrounding the core tubes. NOTE: Notice the orientation of the irregularly shaped gasket on the tubes. The gasket must be placed correctly to ensure proper sealing against the body during reinstallation
- Remove the screws and retainers that secure the heater core and tubes to the HVAC housing.
- Remove the mode door actuator if necessary for clearance to remove the core.
- Lift the heater core straight up and out of the HVAC housing.
- When replacing individual tubes, loosen and remove the round tube-to-core clamp, and pull tube from core.
WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. See: Heating and Air Conditioning\Service Precautions
Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.
High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.
- When installing individual tubes, insert tube into core ensuring that tube O-ring is seated in core and not pinched. Hold tube in seated position while installing the round tube-to-core clamp. NOTE: The round tube-to-heater-core clamp should be left loose enough to turn the tube in the core. Position the core in the housing, and then tighten the tube-to-heater-core clamp after orienting the tubes to the molded HVAC housing.
- Lower the heater core into the HVAC housing.
- Install the mode door actuator, if removed from housing for core removal.
- Position the retainers over the heater core tubes. Install and tighten the screws that secure the heater core and retainers to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.) . NOTE: The grounding strap is to be attached to the lower heater core tube retainer.
- Reinstall the HVAC housing to the vehicle. See: Heating and Air Conditioning\Housing Assembly HVAC\Service and Repair
- Position the HVAC housing to the dash panel. Be certain that the evaporator condensate drain tube and the housing mounting studs are inserted into their correct mounting holes.
- Install the HVAC housing mounting nuts to the studs on the passenger compartment side of the dash panel. Tighten the nuts to 4.5 Nm (40 in. lbs.) .
- Connect the HVAC housing wire harness connectors.
- Reinstall the rear floor heat ducts to the center floor heat duct outlets.
- Install and tighten the nuts onto the HVAC housing mounting studs on the engine compartment side of the dash panel. Tighten the nuts to 7 Nm (60 in. lbs.) .
- Reinstall the PCM to the passenger side dash panel in the engine compartment. See: Powertrain Management\Computers and Control Systems\Engine Control Module\Service and Repair
- Reinstall the coolant reserve/overflow bottle to the passenger side inner fender shield. See: Engine, Cooling and Exhaust\Cooling System\Coolant Reservoir
- If the vehicle is equipped with the manual temperature control system, connect the HVAC system vacuum supply line connector to the tee fitting near the heater core tubes.
- Unclamp/unplug the heater core hoses and tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system. See: Engine, Cooling and Exhaust\Cooling System\Service and Repair
- Unplug or remove the tape from the suction line and the evaporator outlet tube fittings. Connect the suction line to the evaporator outlet tube. Tighten retaining nut to 28 Nm (250 in. lbs.) .
- Unplug or remove the tape from the liquid line and the evaporator inlet tube fittings. Connect the liquid line to the evaporator inlet tube. Tighten retaining nut to 28 Nm (250 in. lbs.) .
- Evacuate the refrigerant system. See: Refrigerant\Service and Repair
- Charge the refrigerant system. See: Refrigerant\Service and Repair
- Install the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame\Interior Moulding / Trim\Dashboard / Instrument Panel\Service and Repair\Procedures\Instrument Panel Assembly Replacement
- Connect the battery negative cable.
- Start the engine and check for proper operation of the heating and air conditioning systems.