Aspen 4WD V8-5.7L Hybrid (2009)
Housing Assembly HVAC: Removal and Replacement
Front HVAC Housing Removal
REMOVAL
WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In
addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High
Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive
Systems/Battery System, Hybrid Drive/Service Precautions
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service
Precautions/Warning and See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to follow the warnings and
cautions may result in serious or fatal injury.
WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or
service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to
discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow
these instructions may result in accidental airbag deployment and possible serious or fatal injury.
NOTE: The front HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, recirculation-air
door, mode-air doors, blend-air doors and linkage.
1. On Hybrid Electric Vehicles (HEV) models, disconnect the high voltage battery system using the service disconnect at the battery pack See:
Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair
2. Disconnect the 12 volt battery system.
3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery.
4. Drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair.
5. Remove the A/C expansion valve See: Expansion Valve/Service and Repair/A/C Expansion Valve - Removal.
6. Disconnect the heater hoses from the heater core tubes and install plugs or caps over the heater core tube openings.
7. Remove the four nuts (1) that secure the HVAC housing (2) to the engine compartment side of the dash panel (3).
