Opel Insignia: Repair Instructions

Odor Correction

Eliminating Air Conditioning (A/C) Odor

Odors may be emitted from the heat and air conditioning system primarily at start up in hot, humid climates.

When the blower motor fan is turned on, an unpleasant, musty odor may be released into the passenger compartment. The following conditions may cause the odor:

• Debris is present in the heater and air conditioning evaporator and blower module.
• Microbial growth is on the evaporator core

The following procedures should be completed to eliminate most common sources of odor:

1. Use the scan tool to enable the afterblow function, if heater and air conditioning remote control has this functionality.

2. Ensure that the fresh air inlet is clear of debris.

3. Verify that the heater and air conditioning evaporator and blower module drain is not blocked. If the drain is blocked, remove the debris and dry the heater and air conditioning evaporator and blower module performing the following procedure:

1. Start the engine and allow the engine to reach operating temperature.
2. Open the vehicle windows.
3. Select the hottest temperature setting.
4. Select the recirculation mode.
5. Run the blower motor on high for 10 minutes.

4. If equipped, remove the passenger compartment air filter and examine for debris or odor.

1. Take care upon passenger compartment air filter removal to prevent debris on top of the passenger compartment air filter from falling into the heater and air conditioning evaporator and blower module.
2. If the filter is dirty or suspected as the source of the odor, replace the passenger compartment air filter.
3. If the debris has fallen into heater and air conditioning evaporator and blower module, remove the blower motor to remove the debris.

5. If this procedure is unsuccessful in eliminating the odor, perform the AC Delco Cooling Coil Coating procedure if it is available in your market. If the AC Delco Cooling Coil Coating is not available in your market, perform the water and vinegar solution cleaning procedure.

AC Delco Cooling Coil Coating Procedure

The evaporator core and heater and air conditioning evaporator and blower module should be treated with AC Delco Cooling Coil Coating to eliminate microbial growth. Adhesives, Fluids, Lubricants, and Sealers Perform the following procedure:

1. Disable the air conditioning compressor clutch operation by disconnecting the air conditioning compressor clutch coil electrical connector.

2. Start the engine and let the engine idle.

3. Select the hottest temperature setting.

4. Select the heater and air conditioning evaporator and blower module controls to the recirculation mode.

5. Run the blower motor on high for 10 minutes.

6. Place a drain pan beneath the heater and air conditioning evaporator and blower module drain tube.

7. If equipped, remove the passenger compartment air filter.

8. Place protective shop cloths or equivalent over outlet ducts to prevent overspray.

9. Locate an area in the heater and air conditioning evaporator and blower module downstream of the blower, between the blower motor and the evaporator core. Drill a 3.175 mm (0.125 in) hole where the hole will not interfere with or damage the blower motor, blower motor speed controller, evaporator core, or any other operating part the of system.

10. Set the blower speed to maximum high speed.

11. Set heater and air conditioning evaporator and blower module controls to floor outlet mode.

12. Close all air conditioning outlet vents.

13. Wear an approved respirator mask, safety goggles, and latex gloves when applying the AC Delco Cooling Coil Coating.

14. Insert the applicator extension tube into the hole to the mark on the extension tube, ensuring the spray is aiming the same direction as the airflow. Coating should be applied in 3 second bursts with the nozzle being repositioned within the case between bursts until all 4 ounces of coating are applied.

15. Shut the engine OFF. Allow the vehicle to sit for 3 - 5 minutes.

16. Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.

17. To cure the Cooling Coil Coating:

1. Start the engine and let the engine idle.
2. Lower one side door window 1/2 inch, 12mm.
3. Set the blower speed to maximum high speed.
4. Set heater and air conditioning evaporator and blower module controls to floor outlet mode.
5. Select the hottest temperature setting.
6. Let the vehicle idle for 10 minutes.

18. Reconnect the air conditioning compressor clutch coil electrical connector.

19. Verify proper air conditioning compressor clutch operation.

20. Reinstall the passenger compartment air filter if necessary.

21. Remove the protective shop cloths from inside the vehicle.

22. Ensure the afterblow function has been enabled.

Water And Vinegar Solution Cleaning Procedure

If the AC Delco Cooling Coil Coating is not available perform the following steps:

1. Remove the evaporator core.

2. Clean evaporator core with a solution of 40% vinegar and 60% water.

3. Reinstall the evaporator core.

Refrigerant Recovery and Recharging (R-1234yf)

Special Tools

• GE-45037 A/C Oil Injector
• GE-50078 Electronic Leak Detector
• GE-50300 R-1234yf Air Conditioning Refrigerant Recovery/Recharge Cart
• GE-50744 A/C R-1234yf PAG Oil Injector Hose
• GE-50745 A/C R-1234yf POE Oil Injector Hose
• GE-50957 Machine R-1234yf Contaminated Refrigerant

Equivalent regional tools: Special Tools

Refrigerant label symbols: Refrigerant Label Symbols.

General Information

WARNING: Refer to R-1234yf Proper Service Procedures Warning.

R-1234yf (HFO-1234yf) - 2, 3, 3, 3 - Tetrafluoroprop-1-ene (CF3CFCH2), is an olefin containing hydrogen, fluorine and carbon with thermodynamic properties similar to R-134a. This refrigerant is a mildly flammable gas.

It has a boiling point of -29.2ºC, a vapor pressure of 583 kPa absolute at 20ºC, no ozone depletion potential, and a global warming potential (GWP) of 4.

R-1234yf supply tank is white with red band to denote flammability.

NOTE: In certain regions, technicians repairing or servicing motor vehicle air conditioning (MVAC) systems must be trained and certified by the appropriate regional or national regulatory agency.

• In the USA, refer to the EPA website for MVAC training requirements.
• In Canada, refer to the Environment Canada website for MVAC training requirements.
• In Europe, refer to Commission Regulation (EC) No 307/2008 for MVAC training requirements.

MVAC service shops must certify to the EPA that they have acquired and are properly using approved refrigerant recovery equipment. Service shops must also verify (with on site documentation) that each person using the equipment has been properly trained and certified. MVAC service shops must maintain records of the names and addresses of facilities to which the refrigerant they recover is sent.

Vehicles equipped with R-1234yf refrigerant systems have unique low and high side service fittings.

The proper handling procedures should be followed for all refrigerants as designated by the refrigerant manufacturer's Material Safety Data Sheet (MSDS).

Refrigerant Recovery and Recharging

To remove, recycle and install R-1234yf from/to a vehicles refrigerant system only use GE-50300 R-1234yf Air Conditioning Refrigerant Recovery/Recharge Cart or refrigerant recovery recharge equipment certified to meet the requirements of Society of Automotive Engineers (SAE) J2843 and approved by the EPA.

To remove contaminated refrigerant from a vehicles refrigerant system use GE-50957 Machine R-1234yf Contaminated Refrigerant or only service equipment designed for contaminated refrigerant removal and certified to meet the requirements of SAE J2851. Refrigerant recovered by this equipment cannot be reused or recycled on site and must be sent to an EPA approved reclamation facility for reprocessing or disposal.

To prevent accidental release of refrigerant and minimize safety concerns, the installation of any refrigerant service equipment to the vehicle shall only be done with the engine off and after the refrigerant high side pressure has been reduced (approximately 2 - 3 minutes).

Open the windows and/or doors before charging the vehicle to prevent an accumulation of refrigerant in case of a major refrigerant leak.

WARNING: R-1234yf is heavier than air and may accumulate in low or pit areas - make sure these areas are properly ventilated. Failure to follow this precaution may cause personal injury.

Refrigerant service equipment is required to ensure adequate refrigerant recovery to reduce emissions and provide for accurate recharging of mobile air conditioning systems. Venting refrigerant to the atmosphere is illegal per United States Environmental Protection Agency (EPA) Clean Air Act Section 608.

WARNING: To prevent personal injury, avoid breathing any refrigerant vapor and lubricant mist. Servicing of R-1234yf systems shall only be done in well ventilated work areas. To remove R-1234yf refrigerant from the A/C refrigerant system, recover using SAE J2843 certified equipment. Un-controlled release of R-1234yf refrigerant in the work area may result in high concentrations of R-1234yf that can be flammable. If an accidental system discharge occurs, ventilate the work area before continuing service. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

WARNING: For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained.

CAUTION: Air Conditioning (A/C) desiccant must be replaced if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the A/C desiccant will result in damage to the A/C refrigerant system. CAUTION: Use only the refrigerant and the charge amount specified in "Refrigerant System Specifications" found in HVAC Service Manual or the vehicles under hood refrigerant label. Use of incorrect refrigerant or charge amounts may result in poor system performance and premature system failure. CAUTION: Use only the lubricant specified for this vehicles refrigerant system. Do not mix refrigerant oils which may result in system contamination and unknown reaction by-products which may cause HVAC System failure.

To protect the refrigerant supply GE-50300 R-1234yf Air Conditioning Refrigerant Recovery/Recharge Cart or SAE J-2843 equipment requires the refrigerant to be analyzed for purity prior to its recovery or transfer. The equipment is required to receive an acceptable reading from the integrated refrigerant identifier prior to recovery or transfer. An acceptable reading is ≥ 98% -1/+2 R-1234yf.

If an unacceptable reading is received (and the presence of foreign gases detected) the refrigerant is considered contaminated and the equipment will not allow its recovery or transfer to an onboard storage vessel. If refrigerant is contaminated use GE-50957 Machine R-1234yf Contaminated Refrigerant or SAE J2851 compliant equipment to recover for reclamation and/or disposal at an EPA approved facility.

As a safety precaution GE-50300 R-1234yf Air Conditioning Refrigerant Recovery/Recharge Cart or SAE J2843 compliant equipment requires the Mobile Air Conditioning (MAC) system to pass a pre-charge leak test (to detect the possibility of a gross system leak prior to charging, >0.3 g/s) prior to allowing the MAC system to be charged.

The pressurized portion of this test will require the technician set the vehicles Heater, Ventilation and Air Conditioning (HVAC) blower motor on high, A/C switch off and air distribution mode set to floor. The technician shall insert a GE-50078 Electronic Leak Detector or GE-50078 compliant electronic leak detector, set to low sensitivity (14 grams/year leak rate) into the center of a floor duct outlet, as far as possible. When the technician confirms that the vehicle is set up for the pressurized leak check the GE-50300 R-1234yf Air Conditioning Refrigerant Recovery/Recharge Cart will install 15% of the programmed charge into the vehicles refrigerant system. The technician monitors the electronic leak detector for 5 minutes or until the detector alarms.

The equipments display will then ask the following:

1. Was this test performed? If the technician replies Yes, the display next shall ask, 2. Was a leak found? If technician replies Yes, the machine shall only allow recovery and evacuation to allow repair. If the technician replies No, the display shall continue with, 3. Is there an auxiliary evaporator? If the technician replies No the machine shall permit completion of the recharge process. If the technician replies Yes, the display shall instruct the technician to perform a leak check with GE-50078 Electronic Leak Detector or a GE-50078 compliant detector at a rear evaporator outlet, then ask, 4. Was an auxiliary evaporator leak check performed? If the technician replies Yes, the display will continue with Was a leak found? and if the answer is Yes, the machine shall only allow recovery and evacuation to allow repair. If the technician replies No, the machine shall permit completion of the recharge process.

A/C Refrigerant System Oil Charge Replenishing

If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using GE-45037 injector with GE-50744 A/C R- 1234yf PAG Oil Injector Hose or GE-50745 A/C R-1234yf POE Oil Injector Hose. For the proper quantities of oil to add to the A/C refrigerant system, refer to Approximate Fluid Capacities, and Air Conditioning Compressor Oil Balancing.

After completing the recharge process, install and torque the charge port caps to 1.3 N.m (12 lb in).

Flushing

Tools Required

• GE-45268 Air Conditioning Flushing Adapter Kit
• GE-41447-a Leak Detection Dye
• GE-50078 Electronic Leak Detector
• GE-50300 Air Conditioning Service Center for HFO1234-yf

General Information

R-1234yf (HFO-1234yf) - 2, 3, 3, 3 - Tetrafluoroprop-1-ene (CF3CFCH2), is an olefin containing hydrogen, fluorine and carbon with thermodynamic properties similar to R-134a. This refrigerant is a mildly flammable gas.

It has a boiling point of -29.2ºC, a vapor pressure of 583 kPa absolute at 20ºC, no ozone depletion potential, and a global warming potential (GWP) of 4.

In certain regions, technicians repairing or servicing motor vehicle air conditioning (MVAC) systems must be trained and certified by the appropriate regional or national regulatory agency.

• In the USA, refer to the EPA website for MVAC training requirements.
• In Canada, refer to the Environment Canada website for MVAC training requirements.
• In Europe, refer to Commission Regulation (EC) No 307/2008 for MVAC training requirements.

WARNING: R-1234yf Proper Service Procedures Warning.

NOTE: Flushing with the GE-50300 Cool Tech Refrigerant Recovery/Recharge Machine is not intended to remove metal from the air conditioning system.

Flushing is intended to remove the following contaminants:

• Contaminated air conditioning oil
• Desiccant, following a desiccant bag failure
• Overcharge of air conditioning oil
• Refrigerant contamination

Metal Contamination

In the event of an A/C Compressor failure, metal will be released throughout the system resulting in contamination of the refrigerant and all system components.

Only install a designated machine for contaminated refrigerant (GE-50957 Machine R-1234yf Contaminated Refrigerant or equivalent service machine designated for contaminated refrigerant). This is critical to meet the requirements of SAE J2851, and so the standard refrigerant service machine is not contaminated thus introducing contamination into other vehicles.

For more information on recovery and recharging when system contamination is present, as well as proper disposal, refer to Refrigerant Recovery and Recharging (R-1234yf).

Components that are to be REPLACED due to metal contamination are as follows:

• Air conditioning compressor
• Metal lines that contain mufflers
• Thermal expansion valve (TXV)
• Receiver/Drier bottle with desiccant bag
• All rubber O-rings and seals
• Schrader valves on service ports

Components that are to be FLUSHED due to metal contamination, and are considered reusable are as follows:

• Basic metal lines that contain no mufflers
• Condenser
• Evaporator

Flushing

NOTE: Warmer engine or ambient temperature decreases the refrigerant recovery time during the air conditioning flush procedure.

NOTE: Minimum flush time for metal contamination should be 25 minutes.

1. Recover the refrigerant.

2. Remove the front air conditioning evaporator thermal expansion valve.

3. Install the J 45268-115 in place of the thermal expansion valve.

4. Remove the air conditioning compressor.

5. Install J 45268-10 to the discharge hose.

6. Install J 45268-10 to the suction hose.

7.

NOTE: Forward flow refrigerant flushing is recommended for contaminated refrigerant or air conditioning oil.

NOTE: The filter inside GE-45268-1 is serviceable. Remove and discard the check valve from the filter.

Service the filter with ACDelco P/N GF 470, before each flush.

1. Connect J 45268-1 to the suction port of J 45268-10.
2. Connect the blue hose from GE-50300 Air Conditioning Service Center for HFO1234-yf to the J 45268-1 flush filter adapter.
3. Connect the red hose from GE-50300 Air Conditioning Service Center for HFO1234-yf to the J 45268-10 flush adapter.

NOTE: Reverse flow refrigerant flushing is recommended for desiccant cartridge failure.

NOTE: The filter inside GE-45268-1 is serviceable. Remove and discard the check valve from the filter.

8. Service the filter with ACDelco P/N GF 470, before each flush.

1. Connect J 45268-1 to the discharge port of J 45268-10.
2. Connect the blue hose from GE-50300 Air Conditioning Service Center for HFO1234-yf to the suction port of J 45268-1 flush adapter.
3. Connect the red hose from GE-50300 Air Conditioning Service Center for HFO1234-yf to the suction port of J 45268-10 flush adapter.

NOTE: The valve on the external refrigerant tank must be closed before starting the flush process.

9. Flush the front air conditioning system by following the instructions supplied with the GE-50300 Air Conditioning Service Center for HFO1234-yf.

NOTE: If the vehicle is equipped with an auxiliary air conditioning system, it will be necessary to flush the front air conditioning system before flushing the auxiliary air conditioning system.

10. Service the filter with ACDelco P/N GF 470 before each flush.

1. Remove J 45268-115 from the front evaporator.
2. Inspect the front air conditioning evaporator thermal expansion valve for debris. Clean or replace as needed
3. Install the front air conditioning evaporator thermal expansion valve.
4. Install J 45268-115 in place of the auxiliary air conditioning evaporator thermal expansion valve.

11. Flush the auxiliary air conditioning system by following the instructions supplied with the GE-50300 Air Conditioning Service Center for HFO1234-yf.

12. Remove J 45268-10 from the discharge hose.

13. Remove J 45268-10 from the suction hose.

NOTE: Flushing will remove all the air conditioning oil from the air conditioning system. The air conditioning system must be replenished with the correct amount of air conditioning oil.

14. If the removed air conditioning compressor is being reinstalled, perform the following procedure:

NOTE: Rotate the compressor input shaft to assist in draining the air conditioning oil from the compressor.

1. Drain the air conditioning oil from the air conditioning compressor.

CAUTION: Refer to Correct Refrigerant Lubricant Caution.

2. Add the total system capacity of air conditioning oil to the air conditioning compressor.

15. Refill the air conditioning system with the proper amount of air conditioning oil.

16. If the removed air conditioning compressor is being reinstalled, perform the following procedure:

1. Drain the air conditioning oil from the air conditioning compressor.

CAUTION: Refer to Correct Refrigerant Lubricant Caution.

2. Add the total system capacity of air conditioning oil to the air conditioning compressor.

17. If you will replace the air conditioning compressor after flushing the system, perform the following procedure:

1. DO NOT drain the new air conditioning oil from the compressor.
2. Deduct the amount of air conditioning oil shipped with the service compressor from the amount of air conditioning oil listed in the approximate fluid capacities table.

CAUTION: Refer to Correct Refrigerant Lubricant Caution.

18. Add the calculated amount to the compressor, as needed.

NOTE: GE-41447-a leak detection dye is for PAG oil only.

19. Add one bottle of GE-41447-a leak detection dye directly to the air conditioning compresor.

20. Install the air conditioning compressor.

21. Replace the air conditioning receiver and dehydrator.

22. Remove J 45268-115.

23. Install the auxiliary air conditioning evaporator thermal expansion valve.

24. Evacuate and recharge the air conditioning system.

25. Leak test the fittings using GE-50078 Electronic Leak Detector..

Air Conditioning Compressor Oil Balancing

Draining Procedure

NOTE: Drain and measure as much of the refrigerant oil as possible from the rear head ports of the REMOVED compressor.

1. Remove the compressor crankcase oil drain plug from the removed compressor and drain the refrigerant oil from the crankcase into a clean, graduated container.

2.

Drain the oil from both the suction and discharge ports into the same container. Rotate the compressor shaft to assist in draining the compressor.

3. Measure and record the amount of oil drained from the removed compressor. In addition, measure and record the amount of oil recovered during refrigerant recovery.

This measurement will be used during installation of the replacement compressor.

4. Inspect oil drained from removed compressor.

5. Properly discard the used refrigerant oil.

Balancing Procedure

NOTE: The refrigerant oil in the A/C system must be balanced during compressor replacement.

NOTE: Check the oil volume in the replacement compressor.

The replacement compressor is shipped partially filled with refrigerant oil. The amount of oil has to be balanced according to below:

1. Refer to the amounts of refrigerant oil recorded during the compressor removal and refrigerant recovery.

2. If the sum of the amount of oil drained from the removed compressor and the amount of oil removed during refrigerant recovery is:

• Less than the oil volume in the replacement compressor, no balancing is required. Refill the replacement compressor with the amount removed. It contains the proper amount of oil.
• More than the oil volume in the replacement compressor, additional oil is required. Subtract the oil volume in the replacement compressor from the sum of removed oil (oil drained + oil recovered).

  This calculated difference is the amount of service oil that needs to be added to the replacement compressor. Add the additional oil needed and install the replacement compressor.

AIR CONDITIONING COMPRESSOR REPLACEMENT (LTG)

Preliminary Procedures

1. Refrigerant Recovery and Recharging (R-1234yf),

2. Drive Belt Replacement,

3. Charge Air Cooler Inlet Air Tube Replacement,

4. Air Conditioning Compressor and Condenser Hose Replacement (LGX)Air Conditioning Compressor and Condenser Hose Replacement (LTG)@Air Conditioning Compressor - Disconnect,

1. Air Conditioning Compressor Nut
   CAUTION: Fastener Caution
   Tighten
   22N.m (16 lb ft)
2. Air Conditioning Compressor Bolt[2x]
   Tighten
   22N.m (16 lb ft)
3. Air Conditioning Compressor

Procedure

1. Disconnect the electrical connector.
2. When replacing the air conditioning compressor, balance the compressor oil.
3. Using the GE 39400-A Electronic Halogen Leak Detector leak test A/C compressor fittings.

Special Tools

GE 39400-A Electronic Halogen Leak Detector

Equivalent regional tools:Special Tools

AIR CONDITIONING COMPRESSOR REPLACEMENT (LGX)

Removal Procedure

1. Recover the refrigerant.

2.

Drive Belt(1)@Air Conditioning Compressor - Remove.

3. Front End Sheet Metal Diagonal Brace Reinforcement - Remove.

4.

Air Conditioning Compressor Hose(2)@Air Conditioning Compressor - Remove.

5.

Disconnect the electrical connectors.(1)[2x].

6. Engine Wiring Harness Bracket Bolt(3)@Air Conditioning Compressor - Remove.

7. Air Conditioning Compressor Bolt(2)@Air Conditioning Compressor - Remove.

8.

Air Conditioning Compressor Nut(2)@Air Conditioning Compressor(3) - Remove.

9. Air Conditioning Compressor Stud(1)@Air Conditioning Compressor(3) - Remove.

10. Air Conditioning Compressor Bolt(4)@Air Conditioning Compressor(3) - Remove.

11. Remove the air conditioning compressor (3) from the vehicle.

Installation Procedure

1. Prior to installing the air conditioning compressor perform the air conditioning compressor oil balancing procedure.

2.

Install the air conditioning compressor (3) to the vehicle.

CAUTION: Refer to Fastener Caution.

3. Air Conditioning Compressor Stud(1)@Air Conditioning Compressor(3) - Install and tighten 9 N.m (80 lb in).

4. Air Conditioning Compressor Bolt(4)@Air Conditioning Compressor(3) - Install and tighten 22 N.m (16 lb ft).

5. Air Conditioning Compressor Nut(2)@Air Conditioning Compressor(3) - Install and tighten 22 N.m (16 lb ft).

6.

Engine Wiring Harness Bracket Bolt(3)@Air Conditioning Compressor - Install and tighten 9 N.m (80 lb in).

7. Air Conditioning Compressor Bolt(2)@Air Conditioning Compressor - Install and tighten 22 N.m (16 lb ft).

8. Connect the electrical connectors.(1)[2x].

9.

Air Conditioning Compressor Hose(2)@Air Conditioning Compressor - Install.

10. Front End Sheet Metal Diagonal Brace Reinforcement - Install.

11.

Drive Belt(1)@Air Conditioning Compressor - Install.

12. Recharge the refrigerant.

13. Inspect for refrigerant leaks.

Air Conditioning System Seal Replacement

Removal Procedure

1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure.

NOTE: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.

2. Cap or tape the A/C refrigerant components.

3.

Remove the sealing washer (1) from the A/C refrigerant component.

4. Inspect the seal washer for signs of damage to help determine the root cause of the failure.

5. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.

NOTE: DO NOT reuse sealing washer.

6. DISCARD the sealing washer.

Installation Procedure

NOTE: Flat washer type seals do not require lubrication.

1. Inspect the new sealing washer for any signs of cracks, cuts, or damage.

Do not use a damaged sealing 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 sealing washer (1) onto the A/C refrigerant component.

The sealing washer (1) must completely bottom against the surface of the fitting.

NOTE: After tightening the A/C components, there should be a slight sealing gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component.

5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.

AIR CONDITIONING O-RING SEAL REPLACEMENT

Removal Procedure

1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure.

2. Remove the O-ring seal from the A/C refrigerant component.

3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.

4. Inspect the A/C components for damage or burrs. Repair if necessary.

NOTE: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.

5. Cap or tape the A/C refrigerant components.

6. Discard the O-ring seal.

Installation Procedure

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.

NOTE: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system.

4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.

NOTE: DO NOT reuse O-ring seals.

5. Carefully slide the new O-ring seal onto the A/C refrigerant component.

6.

The O-ring (1) seal must be fully seated.

7. Assemble the A/C components.

AIR CONDITIONING COMPRESSOR HOSE REPLACEMENT

Removal Procedure

WARNING: Refer to R-1234yf Proper Service Procedures Warning.

1. Recover the refrigerant.

2.

Air Conditioning Compressor Hose Nut(1)@Air Conditioning Refrigerant Heat Exchanger - Remove.

3. Air Conditioning Compressor Hose(2)@Air Conditioning Refrigerant Heat Exchanger - Remove.

4. Remove and DISCARD the sealing washer.(3).

5.

Air Conditioning Compressor Hose Nut(1)@Camshaft Cover - Remove.

6. Air Conditioning Compressor Hose(2)@Camshaft Cover - Remove.

7.

Front Bumper Fascia Lower Stiffener(2)@Front Bumper Fascia - Remove.

8.

Air Conditioning Compressor Hose Nut(3)@Air Conditioning Condenser - Remove.

9. Air Conditioning Compressor Hose(2)@Air Conditioning Condenser - Remove.

10. Remove and DISCARD the sealing washer.(1).

11.

Air Conditioning Compressor Hose Nut(1)@Air Conditioning Compressor - Remove.

12. Air Conditioning Compressor Hose(2)@Air Conditioning Compressor - Remove.

13. Remove and DISCARD the sealing washer.(3)[2x].

14.

Disconnect the generator electrical connectors.

15.

Battery Positive Cable Retainer(4) - Disengage.

16. Remove the air conditioning compressor hose (2) from the vehicle.

Installation Procedure

1. Install the air conditioning compressor hose to the vehicle.

2.

Battery Positive Cable Retainer(4) - Engage.

3.

Connect the generator electrical connectors.

4.

Install NEW sealing washers.(3)[2x].

5. Air Conditioning Compressor Hose(2)@Air Conditioning Compressor - Install.

CAUTION: Refer to Fastener Caution.

6. Air Conditioning Compressor Hose Nut(1)@Air Conditioning Compressor - Install and tighten 22 N.m (16 lb ft).

7.

Install a NEW sealing washer.(1).

8. Air Conditioning Compressor Hose(2)@Air Conditioning Condenser - Install.

9. Air Conditioning Compressor Hose Nut(3)@Air Conditioning Condenser - Install and tighten 22 N.m (16 lb ft).

10.

Front Bumper Fascia Lower Stiffener(2)@Front Bumper Fascia - Install.

11.

Air Conditioning Compressor Hose(2)@Camshaft Cover - Install.

12. Air Conditioning Compressor Hose Nut(1)@Camshaft Cover - Install and tighten9 N.m (80 lb in).

13.

Install a NEW sealing washer.(3).

14. Air Conditioning Compressor Hose(2)@Air Conditioning Refrigerant Heat Exchanger - Install.

15. Air Conditioning Compressor Hose Nut(1)@Air Conditioning Refrigerant Heat Exchanger - Install and tighten22 N.m (16 lb ft).

16. Recharge the refrigerant.

17. Check for refrigerant leaks.

AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LGX)

Removal Procedure

1. Recover the refrigerant.

2. Front Bumper Fascia - Remove.

3.

Air Conditioning Condenser Nut(2) - Remove.

4. Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Condenser - Remove.

5.

Air Conditioning Compressor and Condenser Hose Bracket Nut(1) - Remove.

6. Disconnect wiring harness at the generator.

7.

Air Conditioning Compressor and Condenser Hose Nut(1) - Remove.

8. Air Conditioning Compressor and Condenser Hose(2)@Air Conditioning Compressor - Remove.

9.

Air Conditioning Evaporator Hose Nut(2)@Air Conditioning Compressor and Condenser Hose(1) - Remove.

10. Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Evaporator Tube(3) - Remove.

11. Remove the air conditioning compressor and condenser hose (1) from the vehicle.

12. Air Conditioning System Sealing Washer - Remove and DISCARD.

Installation Procedure

1. Install NEW sealing washers. Air Conditioning System Seal Replacement.

2. Install the air conditioning compressor and condenser hose into the vehicle.

3.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Evaporator Tube(3) - Install.

CAUTION: Refer to Fastener Caution.

4. Air Conditioning Evaporator Hose Nut(2)@Air Conditioning Compressor and Condenser Hose(1) - Install and tighten19 N.m (14 lb ft).

5.

Air Conditioning Compressor and Condenser Hose(2)@Air Conditioning Compressor - Install.

6. Air Conditioning Compressor and Condenser Hose Nut(1) - Install and tighten 22 N.m (16 lb ft).

7.

Air Conditioning Compressor and Condenser Hose Bracket Nut(1) - Install and tighten 9 N.m (80 lb in).

8. Install wiring harness at the generator.

9.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Condenser - Install.

10. Air Conditioning Condenser Nut(2) - Install and tighten19 N.m (14 lb ft).

11. Recharge the refrigerant. Refrigerant Recovery and Recharging (R-1234yf).

12. Inspect for refrigerant leaks.

13. Front Bumper Fascia - Install.

AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LTG)

Removal Procedure

1. Recover the refrigerant.

2. Air Cleaner Assembly - Remove.

3. Front Bumper Fascia - Remove.

4.

Air Conditioning Condenser Nut(2) - Remove.

5. Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Condenser - Remove.

6.

Air Conditioning Compressor and Condenser Hose Bolt(1) - Remove.

7. Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Compressor - Remove.

8.

Air Conditioning Compressor and Condenser Hose Bracket Bolt(1) - Remove.

9.

Air Conditioning Evaporator Hose Nut to Air Conditioning Compressor and Condenser Hose(2) - Remove.

10. Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Evaporator Tube(3) - Remove.

11. Remove and DISCARD the sealing washer.

Installation Procedure

1. Install NEW sealing washers.

2.

CAUTION: Fastener Caution

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Evaporator Tube(3) - Install.

3. Air Conditioning Evaporator Hose Nut to Air Conditioning Compressor and Condenser Hose(2) - Install and tighten 19N.m (14 lb ft).

4.

Air Conditioning Compressor and Condenser Hose Bracket Bolt(1) - Install and tighten 9N.m (80 lb in).

5.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Compressor - Install.

6. Air Conditioning Compressor and Condenser Hose Bolt(1) - Install and tighten19N.m (14 lb ft).

7.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Condenser - Install.

8. Air Conditioning Condenser Nut(2) - Install and tighten 19N.m (14 lb ft).

9. Front Bumper Fascia - Install.

10. Air Cleaner Assembly - Install.

11. Recharge the refrigerant.

Air Conditioning Evaporator Tube Replacement (LTG)

Removal Procedure

1. Recover the refrigerant.

2.

Air Cleaner Assembly(1) - Remove.

3. Front Compartment Air Deflector - Remove.

4. Front Wheelhouse Liner-Right Side - Remove.

5. Front Bumper Fascia - Remove.

6.

Engine Mount-Right Side(3) - Remove.

7.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Condenser - Remove.

8.

Air Conditioning Evaporator Tube(1) - Remove.

9. Remove and DISCARD the sealing washer.(2).

10.

Air Conditioning Evaporator Tube(1)@Front End Upper Tie Bar - Remove.

11.

Air Conditioning Evaporator Tube(1)@Front Compartment Inner Side Rail - Remove.

12.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Evaporator Tube - Remove.

13.

Air Conditioning Evaporator Tube Nut(2) - Remove.

14. Air Conditioning Evaporator Tube(1)@Front Compartment Inner Side Rail - Remove.

15.

Air Conditioning Evaporator Tube Nut(3) - Remove.

16. Air Conditioning Evaporator Tube(2) - Remove.

17. Remove and DISCARD the sealing washer.(1)[2x].

Installation Procedure

1.

Install NEW sealing washers.(1)[2x].

2. Air Conditioning Evaporator Tube(2) - Install.

CAUTION: Refer to Fastener Caution.

3. Air Conditioning Evaporator Tube Nut(3) - Install and tighten19 N.m (14 lb ft).

4.

Air Conditioning Evaporator Tube(1)@Front Compartment Inner Side Rail - Install.

5. Air Conditioning Evaporator Tube Nut(2) - Install and tighten 9 N.m (80 lb in).

6.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Evaporator Tube - Install.

7.

Air Conditioning Evaporator Tube(1)@Front Compartment Inner Side Rail - Install.

8.

Air Conditioning Evaporator Tube(1)@Front End Upper Tie Bar - Install.

9.

Install NEW sealing washers.(2).

10. Air Conditioning Evaporator Tube(1) - Install.

11.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Condenser - Install.

12.

Engine Mount-Right Side(3) - Install.

13.

Air Cleaner Assembly(1) - Install.

14. Recharge the refrigerant.

15. Inspect for refrigerant leaks.

16. Front Bumper Fascia - Install.

17. Front Wheelhouse Liner-Right Side - Install.

18. Front Compartment Air Deflector - Install.

AIR CONDITIONING EVAPORATOR TUBE REPLACEMENT (LGX)

Removal Procedure

1. Recover the refrigerant.

2. Front Compartment Air Deflector - Remove.

3. Front Wheelhouse Liner-Right Side - Remove.

4. Front Bumper Fascia - Remove.

5.

Engine Mount-Right Side(2) - Remove.

6.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Condenser - Remove.

7.

Air Conditioning Evaporator Tube(1) - Remove.

8. Remove and DISCARD the sealing washer.(2).

9.

Air Conditioning Evaporator Tube(1)@Front End Upper Tie Bar - Remove.

10.

Air Conditioning Evaporator Tube(1)@Front Compartment Inner Side Rail - Remove.

11.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Evaporator Tube - Remove.

12.

Air Conditioning Evaporator Tube Nut(2) - Remove.

13. Air Conditioning Evaporator Tube(1)@Front Compartment Inner Side Rail - Remove.

14.

Air Conditioning Evaporator Tube Nut(3) - Remove.

15. Air Conditioning Evaporator Tube(2) - Remove.

16. Remove and DISCARD the sealing washer.(1)[2x]

Installation Procedure

1.

Install NEW sealing washers.(1)[2x].

2. Air Conditioning Evaporator Tube(2) - Install.

CAUTION: Refer to Fastener Caution.

3. Air Conditioning Evaporator Tube Nut(3) - Install and tighten 19 N.m (14 lb ft).

4.

Air Conditioning Evaporator Tube(1)@Front Compartment Inner Side Rail - Install.

5. Air Conditioning Evaporator Tube Nut(2) - Install and tighten 9 N.m (80 lb in).

6.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Evaporator Tube - Install.

7.

Air Conditioning Evaporator Tube(1)@Front Compartment Inner Side Rail - Install.

8.

Air Conditioning Evaporator Tube(1)@Front End Upper Tie Bar - Install.

9.

Install NEW sealing washers.(2).

10. Air Conditioning Evaporator Tube(1) - Install.

11.

Air Conditioning Compressor and Condenser Hose(1)@Air Conditioning Condenser - Install.

12.

Engine Mount-Right Side(2) - Install.

13. Recharge the refrigerant.

14. Inspect for refrigerant leaks.

15. Front Bumper Fascia - Install.

16. Front Wheelhouse Liner-Right Side - Install.

17. Front Compartment Air Deflector - Install.

Receiver and Dehydrator Replacement

Preliminary Procedure

1. Recover the refrigerant.

2. Radiator Air Lower Baffle Replacement.

1. Air Conditioning Receiver and Dehydrator Plug
2. Air Conditioning Receiver and Dehydrator Plug Retaining Ring
3. Air Conditioning Receiver and Dehydrator

AIR CONDITIONING EVAPORATOR THERMAL EXPANSION VALVE REPLACEMENT

Preliminary Procedure

1. Refrigerant Recovery and Recharging (R-1234yf).

2. Air Conditioning Evaporator Tube@Air Conditioning Evaporator Thermal Expansion Valve - Remove.

1. Air Conditioning Evaporator Thermal Expansion Valve Bolt[2x]
   CAUTION: Refer to Component Fastener Tightening Caution.
   Tighten 4.7 N.m (42 lb in)
2. Air Conditioning Evaporator Thermal Expansion Valve
3. Air Conditioning Evaporator Thermal Expansion Valve Seal[2x]
   Procedure
   Remove and DISCARD the sealing washer.

AIR CONDITIONING (A/C) REFRIGERANT PRESSURE SENSOR REPLACEMENT

Preliminary Procedure

Front Bumper Fascia Replacement.

1. Air Conditioning Refrigerant Pressure Sensor
   CAUTION: Fastener Caution
   Procedure
   Disconnect the electrical connector.
   Tighten 7N.m (62 lb in)
2. Air Conditioning Refrigerant Pressure Sensor Seal
   Procedure
   1. DISCARD the O-ring seal.
   2. Install a NEW O-ring seal.
   3. Using the GE-39400-A detector and leak test the A/C compressor fittings.

Special Tools
GE-39400-A Electronic Halogen Leak Detector
Equivalent regional tools:Special Tools

AIR CONDITIONING CONDENSER REPLACEMENT

Removal Procedure

1. Recover the refrigerant.

2.

Air Conditioning Evaporator Tube(1)@Air Conditioning Condenser Assembly - Remove.

3.

Radiator Air Upper Baffle(2) - Remove.

4.

Hood Primary Latch Mount Panel Bracket(3) - Remove.

5.

Radiator Air Side Upper Baffle - Right Side(1) - Remove.

6.

Radiator Air Side Upper Baffle - Left Side(1) - Remove.

7. Radiator Air Lower Baffle - Remove.

8.

Air Conditioning Condenser Assembly(1)Remove.

9.

Air Conditioning Condenser Bracket(1) - Remove.

10. Transfer components as necessary.

Installation Procedure

1.

Air Conditioning Condenser Bracket(1) - Install.

2.

Air Conditioning Condenser Assembly(1) - Install.

3. Radiator Air Lower Baffle - Install.

4.

Radiator Air Side Upper Baffle - Left Side(1) - Install.

5.

Radiator Air Side Upper Baffle - Right Side(1) - Install.

6.

Hood Primary Latch Mount Panel Bracket(3) - Install.

7.

Radiator Air Upper Baffle(2) - Install.

8.

Air Conditioning Evaporator Tube(1)@Air Conditioning Condenser Assembly - Install.

9. Recharge the refrigerant.

AIR CONDITIONING CONDENSER BRACKET REPLACEMENT

Removal Procedure

1. Radiator Air Upper Baffle Replacement - Remove.

2.

Air Conditioning Condenser(1) - Remove.

3.

Remove the 2 radiator protector pads (1).

4. Unlock the retaining tabs.

5.

Air Conditioning Condenser Bracket(1)@Radiator - Unclip.

6.

Air Conditioning Condenser Bracket(1) - Remove.

7.

{ If equipped }Auxiliary Radiator(2) - Remove.

Installation Procedure

1.

{ If equipped }Auxiliary Radiator(2) - Install.

2.

Air Conditioning Condenser Bracket(1) - Install.

3.

Air Conditioning Condenser Bracket(1)@Radiator - Install.

4.

Install the 2 radiator protector pads (1).

5.

Air Conditioning Condenser(1) - Install.

6. Radiator Air Upper Baffle Replacement - Install.

HEATER AND AIR CONDITIONING EVAPORATOR AND BLOWER MODULE REMOVAL AND INSTALLATION

Removal Procedure

1. Battery Negative Cable - Disconnect.

2. Recover the refrigerant.

3. Drain the cooling system.

4.

Windshield Garnish Molding(3) - Remove[2x].

5.

Instrument Panel Outer Trim Cover(1, 2) - Remove[2x].

6.

Instrument Panel Compartment(3) - Remove.

7.

Radio(1) - Remove.

8.

Instrument Panel Outer Air Outlet - Right Side(1) - Remove.

9.

Instrument Panel Outer Air Outlet - Left Side(1) - Remove.

10.

Instrument Panel Center Air Outlet Bezel(1) - Remove.

11.

{ If equipped }Instrument Panel Trim Plate(2) - Remove.

12.

Radio Control Assembly (3) - Remove.

13.

Heater and Air Conditioning Remote Control(1) - Remove.

14.

Instrument Panel Center Air Outlet - Left Side(1) - Remove.

15.

Instrument Panel Center Air Outlet - Right Side(1) - Remove.

16.

Steering Column Upper Trim Cover(2) - Remove.

17.

Front Floor Console Trim Plate(2) - Remove.

18.

Instrument Panel Lower Trim Panel(2) - Remove.

19.

Instrument Panel Lower Center Trim Panel(1) - Remove.

20.

Front Floor Console(4) - Remove.

21.

Instrument Panel Knee Bolster(2) - Remove.

22.

Headlamp Switch(1) - Remove.

23.

Instrument Panel Center Trim Plate Applique(2) - Remove.

24.

Hood Primary Latch Release Cable Handle(1) - Loosen.

25.

Instrument Panel Fuse Block Access Hole Cover(2) - Remove.

26.

Remove the 2 diagnostic electrical connector bolts (2).

27. Remove the diagnostic electrical connector (1).

28.

Instrument Cluster(2) - Remove.

29.

{ If equipped }Forward Collision Alert Display Bezel(1) - Remove.

30.

Radio Front Speaker Grille(1) - Remove.

31.

{ LHD }Floor Front Air Outlet Duct - Left Side(2) - Remove.

32.

{ RHD }Floor Front Air Outlet Duct - Right Side(2) - Remove.

33.

NOTE: Do NOT remove the steering wheel from the steering column and do NOT disconnect the steering column from the steering intermediate shaft.

Loosen and carefully lower the steering column.(1).

34.

Heater and Air Conditioning User Interface Control–HVAC Manual(2) - Remove.

35.

Instrument Panel Airbag Bolt(1) - Remove[3x].

36. Disconnect the electrical connector.

37.

Instrument Panel Assembly(1) - Remove.

38.

Windshield Wiper Transmission(2) - Remove.

39.

Air Conditioning Evaporator Tube(2)@Air Conditioning Evaporator Thermal Expansion Valve - Remove.

40.

Heater Inlet Hose(3)@Heater Core Tube - Remove.

41.

Heater Outlet Hose(3)@Heater Core Tube - Remove.

42.

Communication Interface Module Bracket(2) - Remove.

43.

Radio Bracket(2) - Remove.

44.

Front Side Door Sill Garnish Molding(2) - Remove[2x].

45.

Instrument Panel Tie Bar(2) - Remove.

46.

Air Conditioning Evaporator and Blower Module Drain Hose(1) - Remove.

47.

Floor Rear Air Outlet Duct Adapter-Left Side(1) - Remove.

48.

Floor Rear Air Outlet Duct Adapter-Right Side(1) - Remove.

49.

Floor Rear Air Outlet Duct Adapter-Right Side(1) - Remove.

49.

Heater and Air Conditioning Evaporator and Blower Module Nut(1) - Remove.

51.

Heater and Air Conditioning Evaporator and Blower Module(1) - Remove.

52. Transfer components as necessary.

Installation Procedure

1.

Heater and Air Conditioning Evaporator and Blower Module(1) - Install.

2.

CAUTION: Fastener Caution.

Heater and Air Conditioning Evaporator and Blower Module Nut(1) - Install and tighten9N.m (80 lb in).

3.

Front Floor Console Rear Air Front Duct(1) - Install.

4.

Floor Rear Air Outlet Duct Adapter-Right Side(1) - Install.

5.

Floor Rear Air Outlet Duct Adapter-Left Side(1) - Install.

6.

Air Conditioning Evaporator and Blower Module Drain Hose(1) - Install.

7.

Instrument Panel Tie Bar(2) - Install.

8.

Front Side Door Sill Garnish Molding(2) - Install[2x].

9.

Radio Bracket(2) - Install.

10.

Communication Interface Module Bracket(2) - Install.

11.

Heater Outlet Hose(3)@Heater Core Tube - Install.

12.

Heater Inlet Hose(3)@Heater Core Tube - Install.

13.

Air Conditioning Evaporator Tube(2)@Air Conditioning Evaporator Thermal Expansion Valve - Install.

14.

Windshield Wiper Transmission(2) - Install.

15.

Instrument Panel Assembly(1) - Install.

16.

Instrument Panel Airbag Bolt(1) - Install and tighten9N.m (80 lb in).

17. Connect the electrical connector:

18.

Heater and Air Conditioning User Interface Control–HVAC Manual(2) - Install.

19.

Steering Column(1) - Install.

20.

{ RHD }Floor Front Air Outlet Duct - Right Side(2) - Install.

21.

{ LHD }Floor Front Air Outlet Duct - Left Side(2) - Install.

22.

Radio Front Speaker Grille(1) - Install.

23.

{ If equipped }Forward Collision Alert Display Bezel(1) - Install.

24.

Instrument Cluster(2) - Install.

25.

Install the diagnostic electrical connector (1).

26. Install the 2 diagnostic electrical connector bolts (2) and tighten to 2.5N.m (22 lb in).

27.

Instrument Panel Fuse Block Access Hole Cover(2) - Install.

28.

Hood Primary Latch Release Cable Handle(1) - Install.

29.

Instrument Panel Center Trim Plate Applique(2) - Install.

30.

Headlamp Switch(1) - Install.

31.

Instrument Panel Knee Bolster(2) - Install.

32.

Front Floor Console(4) - Install.

33.

Instrument Panel Lower Center Trim Panel(1) - Install.

34.

Instrument Panel Lower Trim Panel(2) - Install.

35.

Front Floor Console Trim Plate(2) - Install.

36.

Steering Column Upper Trim Cover(2) - Install.

37.

Heater and Air Conditioning Remote Control(1) - Install.

38.

Radio Control Assembly (3) - Install.

39.

{ If equipped }Instrument Panel Trim Plate(2) - Install.

40.

Instrument Panel Center Air Outlet - Right Side(1) - Install.

41.

Instrument Panel Center Air Outlet - Left Side(1) - Install.

42.

Instrument Panel Center Air Outlet Bezel(1) - Install.

43.

Instrument Panel Outer Air Outlet - Left Side(1) - Install.

44.

Instrument Panel Outer Air Outlet - Right Side(1) - Install.

45.

Radio(1) - Install.

46.

Instrument Panel Compartment(3) - Install.

47.

Instrument Panel Outer Trim Cover–(1 – 2) - Install.

48.

Windshield Garnish Molding(3) - Install[2x].

49. Fill the cooling system.

50. Recharge the refrigerant.

51. Battery Negative Cable - Connect.

Heater and Air Conditioning Evaporator Case Replacement

Removal Procedure

1. Heater and Air Conditioning Evaporator and Blower Module - Remove.

2.

{ If equipped }Auxiliary Heater Core(2) - Remove.

3.

Heater Core(1) - Remove.

4.

Heater and Air Conditioning Evaporator Case Bolt(1) - Remove[5x].

5.

Heater and Air Conditioning Evaporator Case(1) - Remove.

6. Unlock the retaining tabs.

7. Transfer components as necessary.

Installation Procedure

1.

NOTE: This step only needs to be performed if the vehicle is equipped with an auxiliary heater core.

Cut out the auxiliary heater core cover along the marked line (1) from the new heater and air conditioning evaporator case.

2.

Heater and Air Conditioning Evaporator Case(1) - Install.

3.

CAUTION: Fastener Caution

Heater and Air Conditioning Evaporator Case Bolt(1) - Install and tighten[5x] 2.5N.m (22 lb in).

4.

Heater Core(1) - Install.

5.

{ If equipped }Auxiliary Heater Core(2) - Install.

6. Heater and Air Conditioning Evaporator and Blower Module - Install.

Air Conditioning Evaporator Replacement

Removal Procedure

1. Air Conditioning Evaporator and Blower Case Replacement - Remove.

2.

Heater and Air Conditioning Evaporator and Blower Upper Case Bolt(1) - Remove[11x].

3. Heater and Air Conditioning Evaporator and Blower Upper Case(2) - Remove.

4. Unlock the retaining tabs.

5.

Air Conditioning Evaporator(1) - Remove.

Installation Procedure

1.

Air Conditioning Evaporator(1) - Install.

2.

CAUTION: Fastener Caution

Heater and Air Conditioning Evaporator and Blower Upper Case(2) - Install.

3. Heater and Air Conditioning Evaporator and Blower Upper Case Bolt(1) - Install and tighten[11x] 2.5N.m (22 lb in).

4. Air Conditioning Evaporator and Blower Case Replacement - Install.

AIR CONDITIONING EVAPORATOR AND BLOWER MODULE DRAIN HOSE REPLACEMENT

1. Air Conditioning Evaporator and Blower Module Drain Hose

Procedure

Pull the right front carpet back to access the air conditioning evaporator and blower module drain hose.

CAUTION: Refer to HVAC Module Drain Tube Caution.

HEATER INLET HOSE REPLACEMENT (3.6L LGX)

Removal Procedure

1. Drain the cooling system.

2. Air Cleaner Outlet Duct - Remove.

3.

Heater Inlet Hose Clamp(1) - Disengage.

4. Heater Inlet Hose(2)@Heater Inlet and Outlet Pipe - Remove.

5.

Heater Inlet Hose Clamp(1) - Disengage.

6. Heater Inlet Hose(2)@Heater Core - Remove.

7. Heater Inlet Hose(2) - Remove.

Installation Procedure

1.

Heater Inlet Hose(2)@Heater Core - Install.

2. Heater Inlet Hose Clamp(1) - Engage.

3.

Heater Inlet Hose(2)@Heater Inlet and Outlet Pipe - Install.

4. Heater Inlet Hose Clamp(1) - Engage.

5. Air Cleaner Outlet Duct - Install.

6. Fill the cooling system.

7. Start the engine and check for coolant leaks.

HEATER INLET HOSE REPLACEMENT (2.0L LTG)

Preliminary Procedure

NOTE: The charge air cooler outlet air tube is only removed for clarity in the graphic.

Cooling System Draining and Filling (Static) Cooling System Draining and Filling (GE 47716).

1. Heater Inlet Hose Clamp[2x]
2. Heater Inlet Hose Retainer
   Procedure
   Unlock the retaining tabs.
3. Heater Inlet Hose

HEATER OUTLET HOSE REPLACEMENT (3.6L LGX)

Preliminary Procedures

1. Cooling System Draining and Filling (Static) Cooling System Draining and Filling (GE 47716).

2. Air Cleaner Outlet Duct Replacement.

1. Heater Outlet Hose Clamp[3x]
   Procedure
   Hose Clamp Replacement Guidelines - Spring Type
2. Heater Outlet Hose Retainer
   Procedure
   Unlock the retaining tabs.
3. Heater Outlet Hose
   Preliminary Procedures
   1. Fill the cooling system to the proper level.
   2. Start the engine and check for coolant leaks.

HEATER OUTLET HOSE REPLACEMENT (2.0L LTG)

Preliminary Procedure

NOTE: The charge air cooler outlet air tube is only removed for clarity in the graphic.

Drain the cooling system.

1. Heater Outlet Hose Clamp[3x]
2. Heater Outlet Hose Retainer
   Procedure
   Unlock the retaining tabs.
3. Heater Outlet Hose
   Procedure
   1. Fill the cooling system.
   2. Check the cooling system for leaks.

HEATER COOLANT PUMP HOSE REPLACEMENT

Preliminary Procedure

Cooling System Draining and Filling (Static) Cooling System Draining and Filling (GE 47716).

1. Heater Coolant Pump Hose Clamp[2x]
2. Heater Coolant Pump Hose - Inlet

PASSENGER COMPARTMENT AIR FILTER REPLACEMENT

Preliminary Procedures

Instrument Panel Compartment Replacement.

1. Passenger Compartment Air Filter Housing Cover Screw[2x]
   CAUTION: Fastener Caution.
   Tighten 2.5N.m (22 lb in)
2. Passenger Compartment Air Filter Housing Cover
   Procedure
   Unlock the retaining tabs.
3. Passenger Compartment Air Filter

BLOWER MOTOR CONTROL MODULE REPLACEMENT

1. Blower Motor Control Module Bolt[2x]
   CAUTION: Fastener Caution.
   Tighten 2.5 N.m (22 lb in)
2. Blower Motor Control Module
   Procedure
   1. Disconnect the electrical connectors.
   2. Control Module References - Programming and Setup

BLOWER MOTOR REPLACEMENT

Preliminary Procedures

1. Battery Negative Cable Disconnection and Connection (3.6L LGX) Battery Negative Cable Disconnection and Connection (2.0L LTG).

2. Instrument Panel Lower Trim Panel Insulator Replacement.

1. Blower Motor Bolt[3x]
   CAUTION: Fastener Caution.
   Tighten 2.5 N.m (22 lb in)
2. Blower Motor
   Procedure
   Disconnect the electrical connector.

SIDE WINDOW DEFOGGER OUTLET GRILLE REPLACEMENT

1. Side Window Defogger Outlet Grille[2x]
   Procedure
   Unlock the retaining tabs.

INSTRUMENT PANEL OUTER AIR OUTLET REPLACEMENT - LEFT SIDE

Preliminary Procedure

Loosen the side of the steering column upper trim cover to aid in the removal of the instrument panel outer air outlet.

1. Instrument Panel Outer Air Outlet - Left Side
   Procedure
   1. Unlock the retaining tabs.
   2. Using a flat-bladed plastic trim tool, release the retainer clips.

INSTRUMENT PANEL CENTER AIR OUTLET REPLACEMENT - LEFT SIDE

Preliminary Procedure

Radio Control Assembly Replacement (IOB) Radio Control Assembly Replacement (IO5, IO6).

1. Instrument Panel Center Air Outlet - Left Side
   Procedure
   Unlock the retaining tabs.

INSTRUMENT PANEL CENTER AIR OUTLET REPLACEMENT - RIGHT SIDE

Preliminary Procedure

Radio Control Assembly Replacement (IOB) Radio Control Assembly Replacement (IO5, IO6).

1. Instrument Panel Center Air Outlet - Right Side
   Procedure
   Unlock the retaining tabs.

INSTRUMENT PANEL OUTER AIR OUTLET REPLACEMENT - RIGHT SIDE

1. Instrument Panel Outer Air Outlet - Right Side
   Procedure
   1. Unlock the retaining tabs.
   2. Use a flat bladed plastic trim tool.

INSTRUMENT PANEL COMPARTMENT AIR DUCT REPLACEMENT

Preliminary Procedure

Floor Rear Air Outlet Duct Adapter Replacement (Left Side)Floor Rear Air Outlet Duct Adapter Replacement (Right Side) - Left Side.

1. Instrument Panel Compartment Air Duct Bolt
   CAUTION: Refer to Fastener Caution.
   Tighten 1.5 N.m (13 lb in)
2. Instrument Panel Compartment Air Duct

Floor Front Air Outlet Duct Replacement - Right Side

Preliminary Procedure

Instrument Panel Lower Trim Panel Insulator Replacement.

1. Floor Front Air Outlet Duct Bolt
   CAUTION: Refer to Fastener Caution.
   Tighten 1.5 N.m (13 lb in)
2. Floor Front Air Outlet Duct - Right Side

FRONT FLOOR CONSOLE REAR AIR DUCT REPLACEMENT (FRONT)

Preliminary Procedure

Front Floor Console Replacement.

1. Front Floor Console Rear Air Duct
   Procedure
   Unlock the retaining tabs.

FRONT FLOOR CONSOLE REAR AIR DUCT REPLACEMENT (REAR)

Removal Procedure

1. Front Floor Console Replacement - Remove.

2. Front Floor Console Rear Trim Panel Replacement - Remove.

3.

Front Floor Console Rear Air Duct - Front(1) - Remove.

4. Unlock the retaining tabs.

5.

Front Floor Console Rear Air Duct Retainer(1) - Remove[2x].

6.

Front Floor Console Rear Air Duct - Rear(1) - Remove.

7. Unlock the retaining tabs.

Installation Procedure

1.

Front Floor Console Rear Air Duct - Rear(1) - Install.

2.

Front Floor Console Rear Air Duct Retainer(1) - Install[2x].

3.

Front Floor Console Rear Air Duct - Front(1) - Install.

4. Front Floor Console Rear Trim Panel Replacement - Install.

5. Front Floor Console Replacement - Install.

FRONT FLOOR CONSOLE REAR AIR FRONT DUCT REPLACEMENT

Preliminary Procedure

1. Front Floor Console Replacement.

2. Instrument Panel Compartment Air Duct Replacement.

1. Front Floor Console Rear Air Front Duct
   Procedure
   Unlock the retaining tabs.

FLOOR REAR AIR OUTLET DUCT ADAPTER REPLACEMENT (LEFT SIDE)

1. Floor Rear Air Outlet Duct Adapter - Left Side
   Procedure
   Pull the left front carpet back to access the floor rear air outlet duct adapter.

NOTE: The front floor console is removed for clarity.

FLOOR REAR AIR OUTLET DUCT ADAPTER REPLACEMENT (RIGHT SIDE)

1. Floor Rear Air Outlet Duct Adapter - Right Side
   Procedure
   Pull the right front carpet back to access the floor rear air outlet duct adapter.

NOTE: The front floor console is removed for clarity.

FRONT FLOOR CONSOLE REAR AIR OUTLET REPLACEMENT

Preliminary Procedure

Front Floor Console Rear Trim Panel Replacement.

1. Front Floor Console Rear Air Outlet
   Procedure
   1. Release the plastic retaining tabs.
   2. Transfer components as necessary.

INSTRUMENT PANEL CENTER AIR OUTLET DUCT REPLACEMENT

Preliminary Procedure

Instrument Panel Assembly Replacement.

1. Side Window Defogger Outlet Duct Retainer
2. Instrument Panel Center Air Outlet Duct
   Procedure
   Unlock the retaining tabs.

WINDSHIELD DEFROSTER OUTLET DUCT REPLACEMENT

Preliminary Procedures

1. Side Window Defogger Outlet Duct Replacement - Left Side (Right Hand Drive).

2. Side Window Defogger Outlet Duct Replacement - Right Side.

1. Windshield Defroster Outlet Duct
   Procedure
   Unlock the retaining tabs.

SIDE WINDOW DEFOGGER OUTLET DUCT REPLACEMENT - LEFT SIDE (RIGHT HAND DRIVE)

Preliminary Procedure

Instrument Panel Center Air Outlet Duct Replacement.

1. Side Window Defogger Outlet Duct - Left Side
   Procedure
   Unlock the retaining tabs.

SIDE WINDOW DEFOGGER OUTLET DUCT REPLACEMENT - RIGHT SIDE

Preliminary Procedure

Instrument Panel Center Air Outlet Duct Replacement.

1. Side Window Defogger Outlet Duct - Right Side
   Procedure
   Unlock the retaining tabs.

FLOOR REAR AIR OUTLET DUCT REPLACEMENT - LEFT SIDE

Preliminary Procedure

Front Floor Panel Carpet Replacement - Left Side.

1. Floor Rear Air Outlet Duct - Left Side

FLOOR REAR AIR OUTLET DUCT REPLACEMENT - RIGHT SIDE

Preliminary Procedure

Front Floor Panel Carpet Replacement - Right Side.

1. Floor Rear Air Outlet Duct - Right Side

HEATER CORE REPLACEMENT

Removal Procedure

1. Cooling System Draining and Filling (Static) Cooling System Draining and Filling (GE 47716) - Drain.

2. Brake and Accelerator Pedal Assembly Replacement - Remove.

3. Instrument Panel Tie Bar Replacement - Remove.

4.

Heater Core Cover Screw(1) - Remove.

5. Heater Core Cover(2) - Unclip.

6.

Heater Core Clamp(1) - Unlock[2x].

7.

Heater Core Clamp(2) - Remove[2x].

8. Heater Core Tube(1) - Remove[2x].

9. Heater Core Tube Sealing Ring(3) - Remove and DISCARD[2x].

10.

Heater Core(1) - Remove.

Installation Procedure

1.

Heater Core(1) - Install.

2.

NOTE: Install NEW O-ring seal.

Heater Core Tube Sealing Ring(3) - Install[2x].

3. Heater Core Tube(1) - Install[2x].

4. Heater Core Clamp(2) - Install[2x].

5.

CAUTION: Fastener Caution

Heater Core Cover(2) - Install.

6. Heater Core Cover Screw(1) - Install and tighten 2.5 N.m (22 lb in).

7. Instrument Panel Tie Bar Replacement - Install.

8. Brake and Accelerator Pedal Assembly Replacement - Install.

9. Cooling System Draining and Filling (Static) Cooling System Draining and Filling (GE 47716) - Fill.

AUXILIARY HEATER CORE REPLACEMENT

Preliminary Procedure

Instrument Panel Tie Bar Replacement.

1. Auxiliary Heater Core Screw[2x]
   CAUTION: Fastener Caution.
   Tighten 2.5N.m (22 lb in)
2. Auxiliary Heater Core
   Procedure
   1. Disconnect the electrical connector.
   2. Unlock the retaining tabs.

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