CTS 2003-2005

Removal & Installation

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CAUTION
Before beginning this procedure, refer to the precautions at the beginning of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Recover the refrigerant.
  2.  
  3. Remove the battery.
  4.  
  5. Drain the coolant.
  6.  
  7. Disconnect the heater inlet and outlet hoses.
  8.  
  9. Disconnect both A/C lines at the cowl.
  10.  
  11. Remove both quick joint clamps.
  12.  
  13. Disconnect both A/C lines.
  14.  
  15. Remove the instrument panel carrier.
  16.  
  17. Remove the air inlet assembly.
  18.  
  19. Disconnect the HVAC module electrical connector.
  20.  
  21. Disconnect the HVAC module drain tube from the floor.
  22.  
  23. Press the tab and release the left rear duct from the HVAC module.
  24.  
  25. Press the tab and release the right rear duct from the HVAC module.
  26.  
  27. Disconnect the right rear heater ducts from the HVAC module.
  28.  
  29. Remove the lower left HVAC module mounting nut.
  30.  
  31. Remove the upper left HVAC module mounting nut.
  32.  
  33. Remove the HVAC module from the vehicle.
  34.  
  35. Remove the foam from the A/C lines.
  36.  
  37. Remove the foam from around the heater pipes.
  38.  

To install:

  1. Install the thick foam packing on the heater core pipes.
  2.  
  3. Install the thin foam packing on the heater core pipes.
  4.  
  5. Install the thick foam packing on the A/C lines.
  6.  
  7. Install the thin foam packing on the A/C lines.
  8.  
  9. Install the HVAC module into the vehicle.
  10.  
  11. Install the upper and lower left HVAC module mounting nuts and tighten to 80 inch lbs. (9 Nm).
  12.  
  13. Connect the rear heater ducts to the HVAC module.
  14.  
  15. Connect the drain tube to the bottom of the HVAC module.
  16.  
  17. Connect the drain tube to the floor.
  18.  
  19. Connect the HVAC electrical connector.
  20.  
  21. Install the air inlet assembly.
  22.  
  23. Lubricate the O-rings of the A/C line with refrigerant oil before connecting the A/C lines.
  24.  
  25. Install the A/C line and A/C line quick connect line clamp to the evaporator.
    NOTE
    Press the A/C line quick connect line clamp together until you hear it engage.

  26.  
  27. Connect the heater inlet hose .
  28.  
  29. Install the instrument panel carrier.
  30.  
  31. Install the battery.
  32.  
  33. Fill the coolant.
  34.  
  35. Evacuate and recharge the AC system.
  36.  
  37. Leak test the fittings of the components.
  38.  

 
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