Installation
INSTALLATIONFig. 15 Front Dash Seal Removal.:
1. Install new cowl panel seals on heater core pipes, case drain, and evaporator block.
2. Install HVAC module through the cowl. Install screws and nuts.
Torque: 5 N.m (44 in-lbs)
3. Install fuel vapor line and clip to stud below TXV
4. Connect blower motor and recirc motor electrical connectors.
5. Install wire harness hold down clips on HVAC module.
6. Connect blower motor resistor electrical connector.
7. Install wire harness hold down clips on HVAC module.
8. Rotate windshield defroster nozzle onto mode valve assembly and install screws. Make sure duct is snapped on both sides of HVAC module.
Torque: 2.2 N.m (20 in-lbs)
9. Install center air outlet duct and screws.
Torque: 10 N.m (89 in-lbs)
IMPORTANT: Make sure that plastic right mounting tab is between knee beam and mounting bracket.
10. For SL and SW only, install rear floor heater duct and place on mounting stud.
NOTICE: Be careful not to damage foam seal.
11. Install lower heater duct.
12. Install instrument panel pad/reinforcement assembly.
IMPORTANT: Make sure wiring harnesses and instrument panel junction block are in position.
13. Install and torque nut and bolts.
Torque 10 N.m (89 in-lbs)
14. Connect antenna cable at lower right side of instrument panel reinforcement.
15. Install glove box and snap in at clip locations.
16. Install and torque screws.
Torque: 2.2 N.m (20 in-lbs)
17. Install glove box door stops.
18. Adjust striker as necessary.
19. Install passenger side air bag harness to energy absorber and cross-car beam.
20. Install dimmer switch wiring harness to instrument panel reinforcement.
21. Install instrument cluster.
22. Install and torque screws.
Torque: 3 N.m (26 in-lbs)
23. Connect electrical connectors to instrument cluster.
24. Install CPA.
25. Connect electrical connector to dimmer switch.
26. Install instrument cluster trim bezel. Push in at clip locations.
27. Install push pin fasteners.
28. Raise steering column into position.
29. Install and torque bolts.
Torque: 35 N.m (26 ft-lbs)
30. Connect ignition switch electrical connector at right steering column bolt.
31. Route hood release cable through I/P and then install release cable to lever.
32. Install steering column filler panel and Data Link Connector (DLC).
33. Install and torque screws.
Torque: 2.2 N.m (20 in-lbs)
34. Install and tighten bolts into H-bracket.
Torque: Bolts: 25 N.m (19 ft-lbs)
35. Feed instrument panel junction block through H-bracket towards rear of car.
36. Slide IPJB on mounting pads to lock tabs.
37. Install and tighten IPJB screw.
Torque: 2.2 N.m (20 in-lbs)
38. Connect rear electrical connector to IPJB.
39. Tighten screw.
Torque: 6.5 N.m (5 ft-lbs)
40. Install wiring harness, ground wire and screw to H-bracket.
41. Tighten screw.
Torque: 2.2 N.m (20 in-lbs)
42. Install closeout seal.
IMPORTANT: Make sure tabs engage closeout seal holes on both sides.
43. Install HVAC control.
44. Install and tighten screws.
Torque: 2.5 N.m (22 in-lbs)
45. Install temperature and mode cables over pins.
Cable Identification:
^ Temperature cable - white
^ Mode cable - black
46. Install cable housings into channel and push down to lock.
47. Connect blower switch, A/C-Recirc and lighting electrical connectors.
IMPORTANT: Make sure wiring harnesses do not interfere with control lever movement.
48. Connect electrical connector and antenna to radio.
49. Install radio.
IMPORTANT: Make sure spring clips are seated in D-holes on both sides.
50. Install and tighten screws.
Torque: 2.5 N.m (22 in-lbs)
51. Connect traction control/fog lamp/rear defog electrical connector, if equipped.
52. Install radio/HVAC control cover. Push in at clip locations.
53. Install push pins and lock.
54. Place shifter in neutral.
55. Lower front of console over shifter.
56. Lower rear of console over parking brake lever onto rear mounting pad.
IMPORTANT: Make sure to place window/mirror and ashtray light connectors through openings into position.
57. Move console rearward.
58. Install cigarette lighter bulb through opening and rotate counterclockwise.
59. Connect cigarette lighter electrical connector.
60. Move console forward into position.
IMPORTANT: Make sure upper tabs on front of console engage sheet metal on lower I/P brace.
61. Install and tighten front console screws.
Torque: 1.2 N.m (11 in-lbs)
62. Install left and right lower trim panel extensions by inserting hinges into console openings. Then rotate closed and push in at dual lock locations.
63. For vehicles without console armrest:
a. Align rear of console with pin on mounting pad.
b. Install and tighten screws.
Torque: 1.6 N.m (14 in-lbs)
c. Install screw cover.
64. Connect window/mirror switch electrical connectors.
65. Install window/mirror switch by inserting front edge into opening. Then push rear edge down into position.
66. Insert bulb through opening until bulb socket is flush with cup holder. Push socket down to engage lock tab.
67. Install wiring harness to cup holder.
68. Install cupholder by inserting through console opening and pushing straight down.
69. Install parking brake cover over lever.
70. Install and tighten screw.
NOTICE: Do not overtighten screw or it will pull through cover.
Torque: 1.6 N.m (14 in-lbs)
71. Install arm rest unit into console, if equipped. Install and tighten screws.
Torque: 1.6 N.m (14 in-lbs)
72. Install right and left end cap assemblies.
73. Install and tighten screws.
Torque: 2.2 N.m (20 in-lbs)
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
74. Raise vehicle.
NOTICE: Be careful not to push hoses onto heater core so far that foam seal is unseated.
75. Install hose and clamp on heater core outlet. Position clamp at a 7-8 o'clock position.
76. Install hose and clamp on heater core inlet. Position clamp at a 6 o'clock.
77. Lower vehicle.
NOTICE: Use only R-12 Refrigerant oil (mineral) to lubricate O-rings. Use of R-134a (PAG) oil will cause premature corrosion of fitting joints.
78. Remove protective covers. Lubricate with R-12 Refrigerant oil (mineral) and install new O-rings on evaporator pipes.
79. Install thermal expansion valve (TXV) on evaporator.
Torque: 10 N.m (89 ft-lbs)
NOTICE: Use only R-12 Refrigerant oil (mineral) to lubricate O-rings. Use of R-134a (PAG) oil will cause premature corrosion of fitting joints.
80. Lubricate O-rings with R-12 Refrigerant oil (mineral) and install new O-rings on suction hose and liquid line.
81. Install liquid line on TXV
Torque: 25 N.m (19 ft-lbs)
82. Install suction hose on TXV
Torque: 25 N.m (19 ft-lbs)
83. Install air cleaner housing cover and air induction hose.
84. Fill and pressure test the cooling system.
85. Evacuate, charge, and leak test A/C system. Perform A/C Performance Test.
86. Connect negative battery cable.
Torque: 17 N.m (151 in-lbs)
87. Set clock to proper time if equipped.
88. Enable the Supplemental Inflatable Restraint (SIR) system.
89. Reset radio stations.