Removal
REMOVAL1. Disconnect negative battery cable.
IMPORTANT: Verifying the purity of the refrigerant with a purity identifier before recovery is recommended.
2. Recover refrigerant using an approved refrigerant recovery system. Measure the amount of oil lost during recovery and record.
CAUTION: DO NOT REMOVE HOSES OR LINES BEFORE SYSTEM IS FULLY DISCHARGED.
NOTE: When removing the TXV, keep dirt and foreign material from getting on or into the O-ring sealing surfaces. Clean tools and a clean work area are important for proper service. The TXV seal area should be cleaned before any repairs are begun. The parts must be kept clean at all times and any parts to be assembled should be cleaned with a non-petroleum based solvent and dried with air. Use only lint free cloths to wipe parts. Do not allow solvent to enter evaporator or hoses.
3. Remove suction/liquid line assembly to TXV retaining bolt.
4. Remove suction/liquid line assembly block from TXV by gently rocking while pulling forward.
5. Install cap on suction/liquid line assembly to prevent oil spillage.
6. Install cap on TXV to prevent oil loss and dirt entry.
7. Drain coolant - see "Draining Coolant" in the Cooling System.
8. Remove heater inlet hose from auxiliary water pump outlet on L81 engines, from thermostat outlet on L61 engine.
9. Remove heater return hose from head bridge on L81, block inlet on L61.
10. Place end of heater return hose in a container and apply low pressure (34 kPa, 5 psi) shop air to the heater inlet hose to blow coolant out of heater core.
11. Install heater return hose to nipple and position clamp at 6:00 position on L81, 12:00 position on L61.
12. Install heater inlet hose to auxiliary water pump outlet on 181, thermostat outlet on L61 and position clamps at 12:00.
13. Remove heater inlet hose from heater core pipe by depressing quick connect collar tab, located at 6:00, and pulling black collar towards front of vehicle and then pulling quick connect off of heater core pipe.
14. Remove heater outlet hose from heater core pipe by depressing quick connect collar tab, located at 6:00, and pulling white collar towards front of vehicle and then pulling quick connect off of heater core pipe.
NOTE: Green plastic rings may be found hanging on the pipes after hose removal, these are manufacturing aids and should be discarded.
15. Disable the SIR System. (Refer to "Disabling the SIR System" procedure.) Disabling and Enabling the SIR System
16. Gently pull on left and right side console extensions to remove extensions.
On power windows
17. Using a small flat blade tool, gently pry upward on rear portion of the power window switch to partially disengage switch from console.
18. Disconnect power window switch harness from switch and remove power window switch.
19. Disengage console park brake boot by squeezing the boot in while pulling upward.
20. Lift park brake boot over park brake assembly.
21. Remove front console tray by pulling upward on tray assembly.
22. Disconnect console wiring harness from main body harness.
On automatic transmissions
23. Pull up on PRNDL cover to disengage cover.
On 5-speed transmissions
24. Pull up on shifter boot to disengage boot.
25. Move front seats to forward most position and remove console rear fasteners.
26. Move front seats to rearward most position and remove console front fasteners.
27. Gently lift console up and over shifter or PRNDL cover and remove console assembly.
28. Remove I/P bracket.
29. Remove center trim plate by grabbing trim plate at A/C vent area and gently pulling to disengage attaching clips.
30. Tilt trim plate sideways and disconnect trim plate switch harnesses, then remove trim plate.
31. Remove radio fasteners and partially remove radio to expose radio electrical connections.
32. Disconnect radio electrical connections and ground strap from radio. Then remove radio.
33. Remove HVAC controller fasteners and partially remove controller. Let controller hang loose in I/P opening.
34. Disconnect wiring harness clip to I/P at center outlet.
35. Turn steering wheel to 3 o'clock position.
36. Remove inflator module by inserting a stubby flat blade screw driver into the triangle shaped hole in rear steering wheel shroud.
37. Turn screw driver to release spring fastener, while lifting up on corner of bag closest to that fastener.
38. Repeat for second fastener.
39. Turn steering wheel to 9 o'clock position.
40. Repeat steps until all spring fasteners are released.
41. Disconnect inflator module harness and horn lead.
42. Remove inflator module.
43. Disconnect cruise control (if equipped) switch connection and disconnect harness from steering wheel.
44. Remove steering wheel attachment nut and discard.
45. Install Steering Wheel Puller (KM-210-C or equivalent).
46. Remove steering wheel while feeding the wiring through the wheel opening.
NOTE:
^ Always align the front wheels to the straight-ahead position when installation or removing a coil assembly. If a coil is removed without the wheels in a straight-ahead position and steering wheel has not been moved, the same coil assembly can be reinstalled if coil hub has not been rotated.
^ If yellow tab is not available, use tape to prevent SIR coil from rotating.
47. Insert yellow tab or use a piece of tape to prevent rotating the SIR Coil.
48. Remove upper and lower steering column cover attachments.
49. Remove ignition switch bezel and remove covers.
50. Remove wiper/washer switch and headlamp/turn switch.
IMPORTANT: Cover top of Steering Column.
51. Position steering column to its lowest position.
52. Remove L/S I/P lower dash insulator retainers and let dash insulator hang loose.
53. Remove I/P filler by pulling at attaching clip locations.
54. Remove two upper and two lower I/P trim plate fasteners and remove trim plate.
55. Remove upper and lower cluster fasteners and pull rearward to remove cluster.
56. Disconnect cluster wiring harness from I/P
57. Remove L/S HVAC vent housing and disconnect electrical connections.
58. Remove L/S lower dash insulator retainers and remove insulator.
59. Remove left side lower air outlet duct.
60. Open glove compartment door.
61. Remove glove compartment lamp assembly by pulling on lamp plunger.
62. Disconnect glove compartment lamp wiring harness from glove compartment lamp.
63. Remove R/S I/P lower dash insulator retainers.
64. Pull insulator rearward to detach from forward insulator retainers.
65. Remove R/S heater outlet assembly retainer and remove outlet.
66. Remove glove compartment door.
67. Remove glove compartment bin fasteners.
68. Slowly remove glove compartment bin tilting bin downward to expose the BCM module residing on top of the glove box.
69. Remove BCM module from glove compartment by sliding module out of attaching slots.
70. Remove glove compartment bin.
71. Let body controller hang on body harness.
72. Pull upward at vent locations and remove windshield defroster grille.
73. Unsnap hood release handle from I/P by using a small screwdriver to disengage retainer clips on both sides.
74. Remove diagnostic connection by pulling downward at connector location.
75. Remove I/P harness clips to I/P at lower steering column location.
76. Remove I/P harness clip to I/P behind the glove compartment opening location.
77. Remove fastener at left side I/P to beam location.
78. Remove two fasteners behind cluster location.
79. Remove two fasteners at upper glove compartment location.
80. Remove two fasteners at end bracket location.
81. Remove three fasteners at W/S defroster location.
82. Carefully remove I/P assembly from the vehicle.
83. Disconnect I/P harness electrical harness from module harness.
84. Open drivers side door completely and install protective covering on door inner hinge area to prevent damage to paint.
85. Using a flat blade screwdriver, remove the black plastic beam bolt covers.
NOTE: Use a T30 Torx(TM) socket to prevent stripping out head of bolt.
86. Using a TORX(TM) socket, remove both outer beam bolts. Use caution not to damage door paint.
NOTE: On wagons, the rear washer supply hose is routed through the drivers side A-pillar. Use care not to pinch or damage hose.
87. Install cockpit assembly aid (J 43894) into A-pillar beam bolt holes. Tool flange should fit tight to A-pillar surface when completely installed. This tool is needed to prevent accidentally dropping bolt inside A-pillar.
NOTE: Use a T40 Torx(TM) socket to prevent stripping out head of bolt.
88. Using a TORX(TM) socket, remove both inner beam bolts.
89. Repeat beam bolt removal procedure on passenger's side.
90. Remove cockpit assembly aid (J 43894).
91. Remove I/P beam to steering column brace nuts.
92. Using a large screwdriver, pry steering column braces apart to clear beam studs and remove beam from vehicle.
93. With engine hood open remove wiper arm assemblies.
94. Remove cowl retaining nuts and remove cowl screen assembly.
95. Rotate locking tabs outward to release filter assembly.
96. Remove filter by lifting straight up.
97. Remove filter housing attachment bolts and remove filter housing.
98. Remove evaporator condensate drain tube screw and remove drain tube.
99. Remove HVAC module-to-front of dash bolts.
100. Remove HVAC module from vehicle.