Catera 2000-2001

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disable the SIR system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the heater hose quick connects from the heater core pipes by performing the following procedure:
    1. At the passenger side, raise the air inlet screen and open the access door near the pollen filter.
    2.  
    3. Unlock the quick connect collars by squeezing the tabs and carefully pulling back on the tabs to disconnect the sleeve.
    4.  
    5. If green assembly marks are attached, discard them.
      WARNING
      The front wheels must be maintained in the straight-ahead position and the steering column must be in the LOCK position. Failure to do so will cause improper alignment of some components during installation and may result to damage to the SIR coil assembly.



      Click image to see an enlarged view

      Fig. View of a heater hose connector

    6.  

  10.  
  11. Remove the steering column by removing or disconnecting the following:
    WARNING
    Handle the steering column with care for it is very susceptible to damage. Dropping, leaning or hammering on it could cause damage to its collapsible design.



    Instrument panel driver knee bolster energy absorber and sound insulator
     
    Steering column electrical connector(s)
     
    Coupler bolt from the lower steering column connection and slightly separate the coupler to aid in the shaft removal
     
    Using a chisel and a hammer, rotate the forward support strap shear nut and bolt (located under the steering column) counterclockwise in order to remove them
     
    Steering column-to-rear support bracket bolt
     
    Pull the steering column straight back and through the dash panel and remove it from the vehicle.
     



    Click image to see an enlarged view

    Fig. View of the steering column assembly

  12.  
  13. Remove the instrument panel carrier by removing or disconnecting the following:
    NOTE
    It is not necessary to physically remove the instrument panel but it is necessary to pull the carrier rearward to enable the heater core to be removed from its housing.



    Windshield pillar moldings
     
    Access panel, the air deflector outlet screw, the air deflector outlet and the air outlet duct, located at the right-side of the instrument panel
     
    Instrument panel SIR (air bag) module cover, the instrument panel compartment and the SIR module
     
    Upper center console and the lower center console
     
    Center console air duct screw and the center console air duct
     
    Radio tape player bezel and the radio
     
    Climate control head
     
    Center air outlet deflector, the outlet screws and the outlet housing
     
    Driver-s side access panel
     
    Driver-s side air outlet deflector, the outlet screw and the outlet housing
     
    Driver-s side lower outlet duct
     
    Instrument cluster
     
    Fuse and relay panel screws and the panels
     
    Instrument panel carrier bolts
     
    Electrical connectors from the instrument panel and/or the wiring harness clips from the instrument panel carrier, if necessary
     
    Instrument panel carrier

    Click image to see an enlarged view

    Fig. View of the instrument panel carrier bolt locations

     



    Blower motor housing screws and the housing with the motor
     
    Heater core pipe bracket-to-chassis screw and the bracket
     
    Heater core inlet/outlet pipe bracket-to-heater core screw and the inlet/outlet pipe bracket
     
    Instrument panel support brace bolts from the instrument panel and the transmission well, then remove the brace
     
    Heater core-to-housing retaining screw. Plug the heater core pipes and protect the interior from coolant spills
     
    Heater core and the rubber seal from the heater housing

    Click image to see an enlarged view

    Fig. View of a heater core and seal

     

  14.  

To install:

  1. Install or connect the following:

    Rubber seal and heater core into the heater housing; be careful not to damage the fins
     
    Heater core-to-housing retainer screw
     
    Instrument panel support brace to the transmission well and instrument panel, then torque the bolts to 16 ft. lbs. (22 Nm)
     
    Heater core inlet/outlet pipe bracket to the heater core (using a new O-ring lightly coated with coolant), and torque the screw to 44 inch lbs. (5 Nm)
     
    Heater core pipe bracket with the screw to the chassis, be careful not to strip the screw
     
    Blower motor/housing assembly and torque the screws to 35 inch lbs. (4 Nm)
     
    Instrument panel carrier
     
    Instrument panel carrier by reversing the removal procedures and torque the instrument panel carrier bolts to 16 ft. lbs. (22 Nm)
     

  2.  
  3. Remove the steering column by installing or connecting the following:

    Steering column into the vehicle, through the dash panel and into the lower steering coupling
     
    Hand start the rear support bracket bolt, the forward support strap nut and shear bolt
     
    Rear support bracket bolt. Torque to 16 ft. lbs. (22 Nm)
     
    Forward support strap nut. Torque to 16 ft. lbs. (22 Nm)
     
    New forward support shear bolt. Torque to 15 ft. lbs. (21 Nm)
     
    Lower steering column shaft bolt and torque to 16 ft. lbs. (22 Nm)
     
    Steering column electrical connector(s)
     
    Sound insulator and the instrument panel driver knee bolster energy absorber
     

  4.  
  5. Connect the heater hoses to the heater core pipes by performing the following procedure:
    1. If not attached to the quick connect, discard the green assembly marker(s).
    2.  
    3. Push the quick connects into the pipes until they are fully seated.
    4.  
    5. Squeeze the locking tabs and press the retaining sleeve into the locked position.
    6.  
    7. At the passenger side, close the access door near the pollen filter and lower the air inlet screen.
    8.  

  6.  
  7. Refill the cooling system by performing the following procedure:
    1. Add a 50/50 mixture of water and DEX-COOL® antifreeze to the KALT/COLD mark (seam) on the surge tank.
    2.  
    3. Start the engine and allow it to idle for 1 min.
    4.  
    5. Add more coolant to the surge tank as necessary.
    6.  
    7. Install the radiator sure tank cap.
    8.  
    9. Cycle the engine, from idle to 3000 rpm, in 30 second intervals, until the engine reaches normal operating temperatures.
      NOTE
      The cooling system will bleed itself automatically during warm-up.

    10.  
    11. Turn the engine OFF and recheck the coolant level when the engine is cool
    12.  

  8.  
  9. Connect the negative battery cable.
  10.  
  11. Enable the SIR system.
  12.  
  13. Reprogram the necessary accessories.
  14.  

 
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