INSTALLATION
For installation, reverse the above procedures.
Three holes are provided in evaporator for probe
location. When reinstalling probe, use a different
hole than original one. If a new evaporator is
installed, insert the probe in the uppermost hole pro-
vided.
EXPANSION VALVE
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Recover A/C system refrigerant.
(3) Remove the accessory drive belt.
(4) Remove upper generator bracket.
(5) Disconnect generator field wire connector.
(6) Push generator forward.
(7) Remove ground wire at dash panel.
(8) Remove the nut retaining the refrigerant line
sealing plate to the expansion valve (Fig. 27).
(9) Remove the stud from the expansion valve (Fig.
28).
(10) Carefully pull the refrigerant line sealing
plate assembly from expansion valve towards the
front of the vehicle. Use care not to scratch the
expansion valve sealing surfaces with pilot tubes.
(11) Cover the openings to prevent contamination.
(12) Remove two screws securing the expansion
valve to the evaporator sealing plate (Fig. 28).
(13) Carefully remove expansion valve (Fig. 29).
(14) Remove the old O-rings.
INSTALLATION
(1) Ensure old O-rings are removed. Install new
O-rings on the refrigerant lines and evaporator seal-
ing plate.
Fig. 26 Evaporator ProbeFig. 27 A/C Refrigerant Line Plate
Fig. 28 Expansion Valve Stud and Mounting Screws
Fig. 29 Expansion Valve Removal
NS/GSHEATING AND AIR CONDITIONING 24 - 25
REMOVAL AND INSTALLATION (Continued)
(2) Hand-start the stud into the expansion valve
and torque to7-11N´m(64-96in.lbs.).
(3) Carefully install the expansion valve to the
sealing plate. Install the two screws and tighten 8 to
14 N´m (70 to 130 in. lbs.) torque.
(4) Carefully install the refrigerant lines and seal-
ing plate to the expansion valve. Install the nut and
tighten 20 to 26 N´m (170 to 230 in. lbs.) torque.
(5) Install the ground wire at dash panel.
(6) Pull generator back into the proper position for
bracket mounting.
(7) Install generator field wire connector.
(8) Install the upper generator bracket.
(9) Install accessory drive belt.
(10) Evacuate and recharge system.
(11) After expansion valve is installed, the system
is charged, and leaks have checked repeat the A/C
performance check.
FILTER-DRIER ASSEMBLY
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
(1) Recover A/C system refrigerant.
(2) Remove liquid line at filter-drier (Fig. 21).
(3) Remove the (2) bolts holding filter-drier bracket
to radiator fan module bracket.
(4) Remove the lower liquid line at condenser.
(5) Remove the upper radiator crossmember.
(6) Pull up on radiator and slide filter-drier from
the mounting location.
INSTALLATION
(1) Before installation, replace both refrigerant
line O-rings. Then reverse the above procedures.
(2) Evacuate and recharge system.
HEATER A/C UNIT HOUSING
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY EMPTY BEFORE PROCEEDING.
(1) Set parking brake.
(2) Disconnect battery negative cable.
(3) Using a refrigerant recovery machine, remove
refrigerant from the A/C system.
(4) Remove wiper module. Refer to Group 8K,
Windshield Wipers and Washers.
(5) Drain engine coolant. Remove heater hoses at
the heater core, refer to Heater Hoses Removal and
Installation procedures. Plug coolant lines.(6) Remove suction and liquid lines at the expan-
sion valve (Fig. 27).
(7) Remove the Instrument Panel Assembly. Refer
to Group 8E, Instrument Panel and Systems.
(8) Remove heater ducts.
(9) Disconnect the two upper mounts from the
upper reinforcement and the lower mount from the
tunnel.
(10) Remove the (3) nuts (in the engine compart-
ment) securing the unit to the dash panel (Fig. 30).
(11) Disconnect the HVAC housing wiring harness.
(12) Pull the entire unit rearward until the studs
on the unit clear the dash panel. Drop the unit down.
Pull it rearward to remove it from vehicle.
INSTALLATION
(1) For installation of the assembly, reverse the
above procedures. Install new O-rings on plumbing
inlets
(2) Evacuate and recharge the A/C system.
(3) Perform HVAC control Calibration Diagnostic
and Cooldown test.
HEATER CORE
REMOVAL
(1) Drain coolant system.
(2) Remove left side lower column cover.
(3) Remove steering column assembly. Refer to
Group 19, Steering for service procedure.
(4) Remove ABS module, bracket and wiring (Fig.
31).
(5) Remove I/P to body harness interconnect and
bracket (Fig. 32).
(6) Remove lower silencer boot at base of steering
shaft (Fig. 33)
(7) Pinch off heater lines under the hood.
Fig. 30 HVAC Bolt-Up
24 - 26 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Disconnect both cables from battery, negative
cable first.
(2) Remove 2 screws holding PDC to bracket,
swing out of way.
(3) Remove nut and clamp holding battery to bat-
tery tray (Fig. 5).
(4) Remove battery from vehicle.
(5) Disconnect two vacuum hoses at EVM (Fig. 6).
(6) Remove mounting screws of EVM.
(7) Remove the EVM to gain access to the EVM
electrical connector.
(8) Remove electrical connector at EVM.
INSTALLATION
(1) Install electrical connector to EVM.
(2) Install EVM and tighten mounting screws.
(3) Connect vacuum hoses.
(4) Install PDC to bracket and tighten mounting
screws.
(5) Install battery.
(6) Connect battery cables positive first.
SPECIFICATIONS
TORQUE CHARTÐ2.5L DIESEL
Description Torque
EGR Valve Mounting Bolts..............23N´m
(204 in. lbs.)
EGR Tube Mounting Bolts..............23N´m
(204 in. lbs.)
EVM (Electric Vacuum
Modulator) Mounting Bolt. . . . 2 N´m (20 in. lbs.)
Fig. 5 Battery ClampFig. 6 EVM Location
25 - 8 EMISSION CONTROL SYSTEMNS/GS
REMOVAL AND INSTALLATION (Continued)
