Aura, Outlook 2007

Removal & Installation

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  1. Disable the SIR system.
  2.  
  3. Remove the HVAC module assembly as follows:
    1. Remove the air conditioner (A/C) lines from the thermal expansion valve
    2.  
    3. Recover the refrigerant.
    4.  
    5. Remove the surge tank from the surge tank bracket.
    6.  
    7. Remove the suction line from the dash clip.
    8.  
    9. Remove the liquid line from the dash clip.
    10.  
    11. Remove the liquid line and suction line nut from the thermal expansion valve (TXV).
    12.  
    13. Remove the suction line from the TXV.
    14.  
    15. Remove the liquid line from the TXV.
    16.  
    17. Remove the TXV screws.
    18.  
    19. Remove the TXV.
    20.  

    21. NOTE
      Cap all A/C components immediately to prevent system contamination.

    22.  
    23. Remove and discard the sealing washers.
    24.  
    25. Remove the heater hose from the heater core.

      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel assembly

    26.  
    27. Instrument panel (I/P) assembly by removing the following:

      Windshield garnish molding
       
      Instrument panel upper trim panel
       
      Instrument panel outer trim covers
       
      Instrument panel cluster trim plate bezel
       
      Instrument panel cluster assembly
       
      Console assembly
       
      Remove the knee bolster
       
      Instrument panel center molding assembly
       
      HVAC control module
       
      Radio assembly
       
      Instrument panel compartment assembly
       
      Center air outlet assembly
       
      Note location and routing of the instrument panel wiring harness prior to removal of the instrument panel assembly to ensure proper reinstallation
       
      Wiring harness from the instrument panel assembly
       
      Instrument panel assembly from the vehicle with the aid of an assistant

      Click image to see an enlarged view

      Fig. Exploded view of the windshield garnish molding



      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel upper trim panel



      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel outer trim panel



      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel cluster trim plate bezel



      Click image to see an enlarged view

      Fig. Removing the console assembly



      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel center molding assembly



      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel compartment assembly

       

    28.  
    29. Remove the hood release handle
    30.  
    31. Remove the steering column.
    32.  
    33. Remove the accelerator pedal assembly.
    34.  
    35. Remove the brake pedal assembly.
    36.  
    37. Remove the body control module bracket.
    38.  
    39. Instrument panel reinforcement assembly bolt
    40.  
    41. Instrument panel lower bracket bolt
    42.  
    43. Instrument panel reinforcement assembly

      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel reinforcement assembly

    44.  
    45. Remove the recirculation actuator wire harness connector.
    46.  
    47. Remove the air temperature actuator wire harness connector.
    48.  
    49. Remove the mode actuator wire harness connector.
    50.  
    51. Remove the blower motor wire harness connector.
    52.  
    53. Remove the blower motor resistor wire harness connector.
    54.  
    55. Remove the left hand side window defogger outlet duct.
    56.  
    57. Remove the HVAC module assembly mounting bolts from the instrument panel reinforcement.
    58.  
    59. Remove the HVAC module assembly to dash panel bolts.
    60.  
    61. Remove the HVAC module assembly.
    62.  
    63. Remove the center floor air outlet duct screws.
    64.  
    65. Remove the center floor air outlet duct.
    66.  
    67. Drill out the heater core cover heat stakes.
    68.  
    69. Remove the heater core cover screws.
    70.  
    71. Remove the heater core cover.
    72.  
    73. Remove the heater core.

      Click image to see an enlarged view

      Fig. Remove the heater core from the HVAC module assembly

    74.  

  4.  

To install:

  1. Installation is the reverse of removal, please note the following:
    1. Tighten the instrument panel lower bracket bolt to 80 in. lbs. (9 Nm).
    2.  
    3. Tighten the instrument panel reinforcement assembly bolts to 18 ft. lbs. (25 Nm).
    4.  
    5. Tighten the instrument panel assembly screws to 18 in. lbs. (2 Nm).
    6.  
    7. Uncap A/C components.
    8.  
    9. Install new sealing washers.
    10.  
    11. Install the TXV.
    12.  
    13. Install the TXV screws.
    14.  
    15. Install the liquid line to the TXV.
    16.  
    17. Install the suction line to the TXV.
    18.  
    19. Install the liquid line and suction line nut to the TXV. Tighten the nut to 15 ft. lbs. (20 Nm).
    20.  
    21. Install the liquid line to the dash clip.
    22.  
    23. Install the suction line to the dash clip.
    24.  
    25. Evacuate and charge the refrigerant system.
    26.  
    27. Leak test the fittings.
    28.  
    29. Install the surge tank to the surge tank bracket.

      Click image to see an enlarged view

      Fig. Installing the TXV assembly

    30.  

  2.  



Click image to see an enlarged view

Fig. Exploded view of the heater core assembly mounting-Outlook

  1. Drain the coolant.
  2.  
  3. Remove heater inlet hose from heater core.
  4.  
  5. Remove heater outlet hose from heater core.
  6.  
  7. Remove left front floor console extension panel.
  8.  
  9. Remove the floor outlet air duct.
  10.  
  11. Reposition any wiring harness to access heater core cover.
  12.  
  13. Remove the heater core cover screw and cover.
  14.  
  15. Remove the heater core tube clips. Cap or plug heater core, hoses and tubes to prevent any fluid leakage. Position tube forward to release from heater core and slide rearward to remove.
  16.  
  17. Reposition the heater core outward from the heater case to ease in removal.
  18.  
  19. Mark the location of the center foam seal from the old heater core to the new heater core.
  20.  

To install:

  1. Installation is the reverse of removal, please note the following:
    1. Press on foam seals to activate adhesive.
    2.  
    3. Keep the heater core horizontal and straight when inserting into the HVAC module in order to prevent foam seal damage.
    4.  
    5. Push heater core until the foam seal around the heater core tank is inserted into the HVAC module and the heater core is fully seated.
    6.  
    7. Always use new seals when connecting hoses and covers.
    8.  

  2.  

 
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