Heater Core Replacement - Auxiliary

REMOVAL PROCEDURE




1. Recover the refrigerant from the A/C system.
2. Drain the engine coolant.
3. Raise the vehicle.
4. Disconnect the heater lines (2,3) from the auxiliary HVAC module at the underside of the vehicle.




5. Disconnect the air conditioning lines (2,3) from the auxiliary HVAC module at the underside of the vehicle.




6. Remove the nuts (2) from the studs (1) that secure the auxiliary HVAC module to the underside of the vehicle.
7. Remove the safety stands.
8. Lower the vehicle.




9. Remove the right rear quarter trim panel.
10. Remove the Real Time Damping (RTD) Module.
11. Disconnect the electrical connectors.
12. Remove the fastener (5) for the upper auxiliary air duct (6). Carefully slide the duct up, into the headliner, until the bottom edge of the duct is above the air distributor duct.




13. Remove the fastener (4) for the lower auxiliary air outlet. (5)




14. Remove the fastener (4) for the air distributor duct (3). Remove the air distributor duct (3).




15. Remove the fasteners (2,4) retaining the rear auxiliary HVAC module to the vehicle.
16. Remove the rear auxiliary HVAC module (3) from the vehicle and place it on a work surface.




17. Remove the air temperature actuator (1) from the module.




18. Remove the stud on the underside of the rear HVAC module between the heater core inlet and outlet pipes.
19. Carefully separate the heater core pipe gasket from the module case and remove the heater core pipe retainer.
20. Remove the rear HVAC module lower cover.




21. Remove the heater core clamp.
22. Remove the heater core from the module.

INSTALLATION PROCEDURE




1. Install the heater core to the module.
2. Install the heater core clamp.




3. Install the rear HVAC module lower cover.
4. Install the heater core pipe retainer and gasket.
5. Install the stud between the heater core inlet and outlet on the underside of the rear HVAC module.




6. Install the air temperature actuator (1) to the module.




7. Install the auxiliary HVAC module assembly (3) to the vehicle.
8. Install the two bolts (2,4) inside the vehicle in order to retain the case to the vehicle.




9. Install the air distributor duct (3) and fastener (4).




10. Install the lower auxiliary air outlet (5) and fastener (4).




11. Install the upper auxiliary air duct (6) to the air distributor duct (3). Install the fastener (5).
12. Connect the electrical connectors.
13. Install the RTD Module.
14. Install the right rear quarter trim panel.
15. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

NOTE: Refer to Fastener Notice in Service Precautions.




16. Install the nuts (2) that secure the auxiliary HVAC module to the vehicle.

Tighten
Tighten the nuts to 9 N.m (80 lb in)




17. Install the air conditioning lines (2,3) and the nut (4) to the auxiliary HVAC module.

Tighten
Tighten the nut to 16 N.m (12 lb ft)




18. Install the heater lines (2,3) to the auxiliary HVAC module at the underside of vehicle.
19. Remove the safety stands.
20. Lower the vehicle.
21. Fill the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
22. Recharge the refrigerant to the system.