Rendezvous 2006-2007

Removal & Installation

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  1. Drain the cooling system.
  2.  
  3. Remove the wiper module.
  4.  
  5. Disconnect the brake booster vacuum hose and reposition.
  6.  
  7. For 3.4L or 3.5L engines, remove the air cleaner outlet duct. For 3.6L engines, remove the air cleaner intake duct.
    WARNING
    For 3.4L engines, disconnect the throttle and cruise control cables from the TBI mounting bracket to prevent bending the cable housings.

  8.  
  9. For 3.4L engines, disconnect the throttle and cruise control cables.
  10.  
  11. Remove the transmission fluid filler tube.
  12.  
  13. Disconnect both of the heater hose clamps at the heater core using the appropriate tool.
  14.  
  15. Disconnect the heater hoses from the heater core.
    WARNING
    Cap off the heater core inlet and outlet pipes to prevent coolant spillage inside of the vehicle.

  16.  
  17. Cap off the heater core pipes.
  18.  
  19. Remove the right IP insulator:
    1. Remove the push-in retainers from the IP insulator to instrument panel.
    2.  
    3. Remove the press-on retainers from the IP insulator to dash mat.
    4.  
    5. Unsnap the IP courtesy lamp from the IP insulator.
    6.  
    7. Remove the IP insulator from the instrument panel.
    8.  

  20.  
  21. Remove the left IP insulator:
    1. Remove the push-in retainers from the IP insulator to instrument panel.
    2.  
    3. Remove the press-on retainers from the IP insulator to dash mat.
    4.  
    5. Unsnap the IP courtesy lamp from the IP insulator.
    6.  
    7. Remove the IP insulator from the instrument panel.
    8.  

  22.  
  23. Remove the center floor air outlet:
    1. Remove the front seats.
    2.  
    3. Remove the floor console bracket.
    4.  
    5. Lift and reposition the front carpet.
    6.  
    7. Remove the center floor duct nuts.
    8.  
    9. Separate the center floor duct from the HVAC module.
    10.  
    11. Separate the center floor duct from the rear floor duct.
    12.  
    13. Remove the center floor duct.
    14.  

  24.  
  25. Remove the screws retaining the heater outlet duct.
  26.  
  27. Remove the heater outlet duct.
  28.  
  29. Remove the IP harness to heater core cover tie strap.
  30.  
  31. Remove the screws retaining the heater core cover.
  32.  
  33. Remove the heater core cover.
  34.  
  35. Remove the heater core pipe retaining screw.
  36.  
  37. Remove the heater core from the HVAC module.
  38.  

To install:

  1. Install the heater core to the HVAC module case.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2.  
  3. Install the heater core pipe retaining clamp screw and tighten the screw to 8 inch lbs. (0.9 Nm).
  4.  
  5. Install the heater core cover.
  6.  
  7. Install the heater core cover retaining screws and tighten the screws to 8 inch lbs. (0.9 Nm).
  8.  
  9. Install the heater outlet duct.
  10.  
  11. Install the heater outlet duct screws and tighten the screws to 8 inch lbs. (0.9 Nm).
  12.  
  13. Install the IP harness to heater core cover tie strap.
  14.  
  15. Install the center floor air outlet:
    1. Install the center floor duct.
    2.  
    3. Connect the center floor duct to the rear floor duct.
    4.  
    5. Connect the center floor duct to the HVAC module.
    6.  
    7. Install the center floor duct nuts and tighten the floor duct nuts to 89 inch lbs. (10 Nm).
      NOTE
      The rear floor air outlet ducts must be aligned with the corresponding holes in the front carpet.

    8.  

  16.  
  17. Reposition the front carpet back into position.
    1. Install the console bracket.
    2.  
    3. Install the front seats.
    4.  

  18.  
  19. Install the left IP insulator:
    1. Snap the IP courtesy lamp into the IP insulator.
    2.  
    3. Position the IP insulator to the instrument panel.
    4.  
    5. Install the push-in retainers to the IP insulator to instrument panel.
    6.  
    7. Install the press-on retainers to the IP insulator to dash mat.
    8.  

  20.  
  21. Install the right IP insulator:
    1. Snap the IP courtesy lamp into the IP insulator.
    2.  
    3. Position the IP insulator to the instrument panel.
    4.  
    5. Install the push-in retainers to the IP insulator to instrument panel.
    6.  
    7. Install the press-on retainers to the IP insulator to dash mat.
    8.  

  22.  
  23. Install the heater hoses to the heater core.
  24.  
  25. Connect the heater hose clamps using the appropriate tool.
  26.  
  27. Install the transmission fluid filler tube.
  28.  
  29. For 3.4L or 3.5L engines, install the air cleaner outlet duct. For 3.6L engines, install the air cleaner intake duct.
  30.  
  31. For 3.4L engines, connect the throttle and cruise control cables to the TBI mounting bracket.
  32.  
  33. Connect the brake booster vacuum hose.
  34.  
  35. Install the wiper module.
  36.  
  37. Fill the coolant.
  38.  

 
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