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Actuator Recalibration When replacing the HVAC control module it will be necessary to allow the HVAC control module to perform a calibration process. When installing the HVAC control module be sure to perform the following: Important: Do not adjust any controls on the HVAC control module while the HVAC control module is self-calibrating. If interrupted, improper HVAC performance will result. 1. 2. 3. 4. 5. 6. 7. Place the ignition switch to the OFF position. Disconnect the scan tool. Install the HVAC control module. Connect all previously disconnected components. Start the vehicle. Wait 40 seconds for the HVAC control module to self-calibrate. Verify that no DTCs have set as current DTCs. When replacing the HVAC actuator it will be necessary to allow the HVAC control module to perform a calibration process. When installing the HVAC actuator be sure to perform one of the following: Important: Do not adjust any controls on the HVAC control module while the HVAC control module is self-calibrating. If interrupted, improper HVAC performance will result. Preferred Method (w/ Scan Tool) Clear all DTCs. Place the ignition switch in the OFF position. Install the HVAC actuator. Connect all previously disconnected components. Start the vehicle. With the scan tool, initiate the Motor Re-calibration feature of the Heating and Air Conditioning Special Functions menu. 7. Verify that no DTCs have set as current DTCs. Important: Do not adjust any controls on the HVAC control module while the HVAC control module is self- calibrating. If interrupted, improper HVAC performance will result. 1. 2. 3. 4. 5. 6. Alternate Method (w/o Scan Tool)

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NOTE: Vehicles may be equipped with an aluminum or a copper brass heater core. Use replacement cores made of copper brass. Always identify the type of core being replaced because there is a difference in the heater core to heater case seals. Having the correct seal is essential to provide satisfactory heater system performance. Identification can be made by looking at one of the core tubes after a hose has been removed. An aluminum core will have a gray colored tube. A copper brass core will have a brass colored tube. If the core is copper brass, the seal removed with the old core can be used with the new copper brass replacement core, providing it is not damaged during removal. If the core is aluminum, a new seal for the copper brass replacement core will be required. REMOVAL 1. Remove the instrument panel, refer to Body and Frame/Interior Trim/ Dash Board/Service and Repair/ See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the evaporator case assembly, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair NOTE: Whenever the evaporator case is removed, it will be necessary to replace the suction accumulator/drier. 3. Remove the vacuum source line from the heater core tube seal.

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The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor, blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Service and Repair/Refrigerant Recovery 4. Remove the front expansion valve from the evaporator tube mounting flange. Install plugs in, or tape over all of the opened refrigerant line fittings. Refer to: Heating and Air Conditioning, Expansion valve, Service and Repair, Expansion Valve Removal and Installation, See: Expansion Valve/Service and Repair 5. Drain the engine cooling system. 6. Disconnect the heater hoses from the heater core tubes.

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Remove the heater-A/C housing from the vehicle, and remove the housing cover. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Heater – A/C Housing Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Heater – A/C Housing Removal and Installation 2. Lift the heater core out of the heater-A/C housing. INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Reassemble and reinstall the heater-A/C housing in the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Heater – A/C Housing Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Heater – A/C Housing Removal and Installation

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There are four carriage bolts which pass through holes in the instrument panel, located around the edges of a large cutout in the panel. This cutout is and opening between the heater blower housing assembly on the engine compartment side of the instrument panel and the evaporator core when air conditioning is provided as an option. This evaporator housing assembly includes other components which are common to heating and air conditioning-heating systems, on the passenger compartment side of the panel. Nut and washer assemblies draw the two major components together through their gaskets at the instrument panel. REMOVAL AND INSTALLATION 1. Drain cooling system. 2. Remove the heater water hoses from the heater core in the engine compartment and plug hoses. 3. Remove modesty panel which runs along the lower edge of the instrument panel (04320). 4. Remove the six screws from the heater core cover (18B300) Fig. 7. located on both sides of the heater assembly case. 5. Remove heater core cover. 6. Remove heater core and heater core case seal (18658) from the heater assembly. 7. Reverse procedure to install, refill cooling system.