Corvette 1997-2005

Removal & Installation

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CAUTION
The air bag system must be disabled before performing service on or around the air bag, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary air bag system repairs.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. If equipped, disable the SIR system by using the following procedure:
    1. Remove the SIR fuse from the fuse panel.
    2.  
    3. Remove the left side sound insulator.
    4.  
    5. Disconnect the Connector Positive Assurance (CPA) from the yellow 2-way SIR harness connector at the base of the steering column and separate the connector.
    6.  
    7. Disconnect the steering wheel module coil connector located at the base of the steering column.
    8.  
    9. Disconnect the CPA from the inflatable restraint instrument panel module connector located at the near the base of the steering column.
    10.  
    11. Disconnect the instrument panel module connector located near the base of the steering column.
    12.  
    13. Disconnect the negative battery cable.
    14.  

  4.  
  5. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Drain the cooling system into a clean container for reuse.
  8.  
  9. Remove or disconnect the following:

    Battery heat shield
     
    Intake manifold
     
    Hose from the right hand air injection check valve
     
    Bolt attaching the right hand air injection check valve to the cylinder head(s), if equipped
     
    Nut attaching the heater pipe bracket to the cowl and set the bracket aside
     
    Heater pipe-to-heater core bolt
     
    Heater pipe assembly from the core, allow any remaining coolant to drain and cap the lines. Discard the sealing washers.
     
    Accumulator hose-to-evaporator bolt
     
    Accumulator hose and evaporator tube from the evaporator. Discard the O-ring seals and cap hose and tube ends and also the evaporator.
     
    HVAC module drain tube from the module
     

  10.  
  11. Remove the following components to access the heater core assembly as follows:
    1. Remove the folding top stowage compartment lid extension by opening the compartment, removing the screws from the lower sides and the top of the panel. Lift the panel up off the bracket.
    2.  
    3. Open the console door.
    4.  
    5. Pull up on the rear of the traction control ride switch to release it from the retaining clips. If the switch will not release, carefully insert a suitable prytool into the recess at the rear of the switch and carefully pull up at the rear of the switch.
    6.  
    7. Disconnect the connector from the traction switch.
    8.  
    9. Disconnect the LED connector from the harness connector and remove the switch.
    10.  
    11. Remove the console retaining nut covers using a suitable prytool.
    12.  
    13. Remove the console retaining nuts.
    14.  
    15. Lift the rear of the console slightly and pull back gently to release the console from under the accessory trim plate.
    16.  
    17. Disconnect the accessory power plug connector, unscrew the plug housing retainer and remove the plug housing.
    18.  
    19. Disconnect the fuel door release electrical connector and if equipped, the rear lift window switch. Remove the switch.
    20.  
    21. Remove the console.
    22.  
    23. Apply the parking brake for additional clearance.
    24.  
    25. Place the transmission in second gear on models with an Automatic Transmission (AT) or fourth on models with a Manual Transmission (MT).
    26.  
    27. On models equipped with MT, grasp the shift control boot and apply light pressure in towards the shift lever to release the tabs from the IP accessory trim plate.
    28.  
    29. Release the remaining tabs using light pressure and remove the boot from the trim plate.
    30.  
    31. Remove the ashtray.
    32.  
    33. Remove the IP accessory trim plate grille.
    34.  
    35. Remove the accessory trim plate screws next to the cigar lighter and behind the ashtray.
    36.  
    37. Remove the accessory trim plate retaining screws in the grille opening.
    38.  
    39. Grasp the sides of the trim plate near the curve at the base.
    40.  
    41. Pull the trim plate rearwards to release the tabs, making sure to lift the rear of the trim plate to clear the driveline tunnel studs.
    42.  
    43. Disconnect the cigar lighter electrical connector.
    44.  
    45. Rotate the shift control boot and reposition one end down into the shifter opening in the trim plate, on models with MT.
    46.  
    47. Lift the trim plate over the shifter and boot and remove the trim plate.
    48.  
    49. Remove the fog lamp, rear compartment lid release switch.
    50.  
    51. Remove the driver knee bolster trim panel screw from behind the switch.
    52.  
    53. Remove the lower driver knee bolster screws,.
    54.  
    55. Grasp the knee bolster trim panel and pull firmly rearward to disengage the locking tabs. Disconnect the connector from the inside air temperature sensor and remove the panel.
    56.  
    57. Open the glove box and disconnect the light switch.
    58.  
    59. Remove the trim plugs from the bottom of the door by reaching behind the door and pushing the plugs out while using a prytool on the front.
    60.  
    61. Remove the lower bolts and the upper and side screws.
    62.  
    63. Slide the glove box forward and unplug the wiring harness connector at the passenger side air bag.
    64.  
    65. Remove the glove box.
    66.  
    67. Remove the inboard side window glass defroster duct from the windshield defroster duct on both sides
    68.  
    69. Remove the DRL electrical connector and the sun load temperature sensor from the windshield defroster duct, if equipped
    70.  
    71. Remove the windshield side garnish moldings.
    72.  
    73. Remove the screws attaching the upper trim pad to the defroster duct.
    74.  
    75. Remove the screws attaching the upper trim pad to the left and right hand hinge pillars.
    76.  
    77. Remove the screws attaching the IP cluster bezel to the upper trim pad.
    78.  
    79. Remove the screws attaching the upper trim panel to the driver knee bolster outer bracket and center support bracket.
    80.  
    81. Remove the screw attaching the upper trim panel to the passenger SIR bracket.
    82.  
    83. Tilt the steering wheel to its lowest position.
    84.  
    85. Lift the rearward edge of the trim panel approximately 2 inches (5 CM) to provide clearance for the air distribution duct.
    86.  
    87. Slowly pull the pad away from the windshield while guiding the tabs past the hinge pillars.
    88.  
    89. Disconnect the remaining electrical connectors to the upper trim panel and remove the panel.
    90.  
    91. Remove the left hand side window defogger outlet duct.
    92.  
    93. Remove the inside air temperature sensor duct.
    94.  
    95. Disconnect the DRL sensor, if equipped.
    96.  
    97. Disconnect the left hand temperature sensor connector, if equipped.
    98.  
    99. Turn the key to the ON position.
    100.  
    101. Using a suitable prytool, depress the park/lock cable retaining tab located on the underside of the ignition switch and pull to release the cable from the ignition switch.
    102.  
    103. Using a suitable prytool, release the tab retaining the park/lock cable to the slot in the shift control cable.
    104.  
    105. Lift the park lock cable from the slot.
    106.  
    107. Grasp the cable end and pull rearwards to unlock the cable from the shifter pivot arm stud.
    108.  
    109. Remove the park/lock cable.
    110.  
    111. Remove the CPA from the electrical connector on the inflatable restraint and Sensing and Diagnostic Module (SDM).
    112.  
    113. Disconnect the SDM.
    114.  
    115. Remove the ignition switch bolts and position the switch aside.
    116.  
    117. Mark the position of the IP center support bracket.
    118.  
    119. Remove the right bolt that attaches the bracket to the driveline tunnel.
    120.  
    121. Remove the bolts that attach the bracket to the passenger knee bolster bracket.
    122.  
    123. Remove the bolt that attaches the bracket to the IP lower support beam.
    124.  
    125. Remove the left bolt that attaches the bracket to the driveline tunnel.
    126.  
    127. Mark the location of the ignition switch bracket.
    128.  
    129. Remove the bolt that attaches the ignition switch housing bracket to the steering column bracket.
    130.  
    131. Remove the bolt that attaches the c enter support bracket to the IP lower support beam.
    132.  
    133. Pull the bracket away from the IP to access the radio control and HVAC connectors.
    134.  
    135. Disconnect connectors from the radio.
    136.  
    137. Disconnect the electrical connectors and vacuum harness connectors from the HVAC control.
    138.  
    139. Disconnect the IP wiring harness and parking brake connector clip from the bracket.
    140.  
    141. Remove the bolts attaching the ignition switch housing bracket to the center support bracket.
    142.  
    143. Note the routing of the IP wiring harness and remove the harness.
    144.  
    145. Remove the center bracket.
    146.  
    147. Remove the left hand floor outlet duct.
    148.  
    149. Remove the right hand side window defogger outlet duct.
    150.  
    151. Remove the SIR bracket and the passenger knee bolster bracket.
    152.  
    153. Disconnect the sunload electrical connector.
    154.  
    155. Disconnect the right hand temperature actuator electrical connector.
    156.  
    157. Remove the right hand floor air duct.
    158.  
    159. Move the carpet away from the right hand side of the driveline tunnel to remove the carpet air duct (rear).
    160.  
    161. Remove the right hand floor air duct (rear).
    162.  
    163. Disconnect the blower motor connector.
    164.  
    165. Remove the blower motor.
    166.  
    167. Disconnect the vacuum supply from the HVAC module.
    168.  
    169. Disconnect the vacuum solenoid connector.
    170.  
    171. Remove the windshield defroster duct.
    172.  
    173. Remove the HVAC module and discard seals.
    174.  
    175. Remove the heater core outlet cover screws and the cover.
    176.  
    177. Remove the heater core cover screws and the cover. Discard the heater core cover seals.
    178.  
    179. Remove and discard the heater core outer seal.
    180.  
    181. Remove the core clamp screw and clamp.
    182.  
    183. Remove the core pipe retaining clamp screw and remove the core from the case.
    184.  
    185. Remove and discard the core lower, center, upper and side seals.
    186.  
    187. Remove the core pipe clamp using a suitable tool.

      Click image to see an enlarged view

      Fig. View of the heater/air conditioning housing assembly-Corvette

    188.  

  12.  

To install:

  1. Install the core pipe clamp.
  2.  
  3. Install new core lower, center, upper and side seals.
  4.  
  5. Install the core in the case.
  6.  
  7. Install the core pipe retaining clamp and screw.
  8.  
  9. Install the core clamp and screw.
  10.  
  11. Install a new heater core outer seal.
  12.  
  13. Install new cavity seals.
  14.  
  15. Install the heater core cover and screws.
  16.  
  17. Install the heater core outlet cover and screws.
  18.  
  19. Install the HVAC module using new seals. Make sure the dashmat is aligned. The opening in the dashmat for the HVAC drain should be aligned so the drain opening in the cowl is approximately centered in the dashmat opening allowing room from the module drain seal to fully align against the cowl. Make sure the heater core joint fitting, condenser fitting module drain and module studs correspond with the openings in the cowl. Insert the left hand stud into the cowl first, then the module drain, then the right hand stud. Install the right hand then the left hand bolts and tighten to 89 inch lbs. (10 Nm).
  20.  
  21. Install the windshield defroster duct.
  22.  
  23. Connect the vacuum solenoid connector.
  24.  
  25. Connect the vacuum supply to the HVAC module.
  26.  
  27. Install the blower motor.
  28.  
  29. Connect the blower motor connector.
  30.  
  31. Install the right hand floor air duct (rear).
  32.  
  33. Install the carpet air duct (rear) and replace carpet.
  34.  
  35. Install the right hand floor air duct.
  36.  
  37. Connect the right hand temperature actuator electrical connector.
  38.  
  39. Connect the sunload electrical connector.
  40.  
  41. Install the SIR bracket and the passenger knee bolster bracket and tighten the bolts to 106 ft. lbs. (12 Nm).
  42.  
  43. Install the right hand side window defogger outlet duct.
  44.  
  45. Install the left hand floor outlet duct.
  46.  
  47. Position the ignition switch housing bracket to the center bracket aligning the marks made during removal, tighten the bolts to 106 inch lbs. (12 Nm).
  48.  
  49. Install the center bracket.
  50.  
  51. Rout the IP wiring harness. Connect the IP wiring harness and parking brake connector clip to the bracket.
  52.  
  53. Connect the electrical connectors and vacuum harness connectors from the HVAC control.
  54.  
  55. Connect connectors to the radio.
  56.  
  57. Install the center support bracket aligning the marks made during removal and tighten the left bolt that attaches the bracket to the IP lower support beam to 106 inch lbs. (12 Nm).
  58.  
  59. Install the ignition switch housing aligning the marks made during removal and tighten the bolt to 17 inch lbs. (2 Nm).
  60.  
  61. Install the left bolt that attaches the bracket to the driveline tunnel and tighten to 106 ft. lbs. (12 Nm).
  62.  
  63. Install the bolt that attaches the bracket to the IP lower support beam and tighten to 106 ft. lbs. (12 Nm).
  64.  
  65. Install the bolts that attach the bracket to the passenger knee bolster bracket and tighten to 106 ft. lbs. (12 Nm).
  66.  
  67. Install the right bolt that attaches the bracket to the driveline tunnel and tighten to 106 ft. lbs. (12 Nm).
  68.  
  69. Install the ignition switch.
  70.  
  71. Connect the SDM.
  72.  
  73. Install the CPA electrical.
  74.  
  75. Route the park/lock cable through the IP center support bracket. Make sure to route the cable under the wiring harness and over the floor rear outlet.
  76.  
  77. Engage the park/lock cable to the ignition switch.
  78.  
  79. Turn the ignition switch OFF.
  80.  
  81. Engage the park/lock cable to the shift control pivot arm stud once aligned pull back to lock.
  82.  
  83. Insert the cable into the slot on the shift control making sure it locks in place.
  84.  
  85. Turn the ignition ON.
  86.  
  87. Place the shift lever in each position but park and try to turn the key to the OFF position.
  88.  
  89. If the key turns to the OFF position except in park the cable is working properly.
  90.  
  91. Place the shift lever in PARK. Turn the key OFF and remove the key.
  92.  
  93. Install the trim panel and attach the hazard warning switch connector.
  94.  
  95. Install the upper trim panel.
  96.  
  97. Install the screws attaching the upper trim pad to the defroster duct.
  98.  
  99. Install the screws attaching the upper trim pad to the left and right hand hinge pillars.
  100.  
  101. Install the screws attaching the upper trim panel to the driver knee bolster outer bracket and center support bracket.
  102.  
  103. Install the screw attaching the upper trim panel to the passenger SIR bracket.
  104.  
  105. Install the screws attaching the IP cluster bezel to the upper trim pad.
  106.  
  107. Install the windshield side garnish moldings.
  108.  
  109. Install the DRL electrical connector and the sun load temperature sensor to the windshield defroster duct, if equipped
  110.  
  111. Install the inboard side window glass defroster duct to the windshield defroster duct on both sides
  112.  
  113. Connect the passenger side air bag connector and install the glove box.
  114.  
  115. Install the upper and side screws and tighten to 7 inch lbs. (2 Nm).
  116.  
  117. Install the lower retaining bolts and tighten to 106 inch lbs. (12 Nm). Install the trim plugs.
  118.  
  119. Connect the light switch and close the door.
  120.  
  121. Connect the inside air temperature switch connector and install the drivers knee bolster trim in position. Insert the connector for the fog lamp, rear compartment lid release switch through the opening in the panel.
  122.  
  123. Install the trim panel and tighten the screws to 16 inch lbs. (1.8 Nm).
  124.  
  125. Install the fog lamp, rear compartment lid release switch.
  126.  
  127. Lower the trim plate over the shifter and under the parking brake lever.
  128.  
  129. Place the shifter boot in position and insert a tool up through the shifter opening in the trim plate.
  130.  
  131. Connect the cigar lighter electrical connector.
  132.  
  133. Install the trim plate into position, install the upper locator tabs and upper locking tabs, then work downwards to engage the remaining tabs.
  134.  
  135. Install the trim plate screws and tighten to 17 inch lbs. (2 Nm).
  136.  
  137. Install trim plate grille.
  138.  
  139. Install the ashtray.
  140.  
  141. Install the shift boot in position and press to engage the tabs.
  142.  
  143. Place the transmission in Park on models with an Automatic Transmission (AT) or reverse on models with a Manual Transmission (MT).
  144.  
  145. Release the parking brake.
  146.  
  147. Install the console.
  148.  
  149. Install the fuel door release electrical switch and if equipped, the rear lift window switch and attach the connections.
  150.  
  151. Install the accessory power plug and attach connector.
  152.  
  153. Slide the console under the accessory trim plate.
  154.  
  155. Install the console retaining nuts.
  156.  
  157. Install the console retaining nut covers.
  158.  
  159. Install the traction switch.
  160.  
  161. Connect the LED connector to the harness connector.
  162.  
  163. Connect the traction switch connector.
  164.  
  165. Engage traction switch to the retaining clips.
  166.  
  167. Close the console door.
  168.  
  169. Install the stowage compartment and tighten the screws to 35 inch lbs. (4 Nm).
  170.  

  1. Install or connect the following:

    Battery heat shield
     
    Intake manifold
     
    Hose to the right hand air injection check valve
     
    Bolt attaching the right hand air injection check valve to the cylinder head(s), if equipped
     
    Heater pipe bracket to the cowl and tighten the bolt
     
    Heater pipe-to-heater core bolt
     
    Heater pipe assembly to the core.
     
    Accumulator hose-to-evaporator bolt
     
    Accumulator hose and evaporator tube to the evaporator using new O-ring seals.
     
    HVAC module drain tube to the module
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Evacuate, charge and leak test the air conditioning system refrigerant.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. If equipped, enable the SIR system by performing the following procedure:
    1. Connect the Connector Positive Assurance (CPA) to the yellow 2-way SIR harness connector at the base of the steering column.
    2.  
    3. Connect the steering wheel module coil connector located at the base of the steering column.
    4.  
    5. Connect the CPA from the inflatable restraint instrument panel module connector located at the near the base of the steering column.
    6.  
    7. Connect the instrument panel module connector located near the base of the steering column.
    8.  
    9. Install the left side sound insulator.
    10.  
    11. Install the SIR fuse to the fuse panel.
    12.  

  10.  
  11. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  12.  

  1. If equipped, disable the SIR system by using the following procedure:
    1. Remove the SIR fuse from the fuse panel.
    2.  
    3. Remove the left side sound insulator.
    4.  
    5. Disconnect the Connector Positive Assurance (CPA) from the yellow 2-way SIR harness connector at the base of the steering column and separate the connector.
    6.  
    7. Disconnect the negative battery cable.
    8.  

  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove the heater/air conditioning housing assembly by removing or disconnecting the following:

    Intake manifold
     
    Heater hoses from the heater core
     
    Refrigerant lines from the evaporator core
     
    Drain tube from the heater/air conditioning housing assembly
     
    Upper instrument pad and the ventilation duct assembly
     
    Electrical connector from the instrument cluster and remove the instrument cluster
     
    Inboard side window glass defroster duct from the windshield defroster duct on both sides
     
    DRL electrical connector and the sun load temperature sensor from the windshield defroster duct, if equipped
     
    Windshield defroster duct from the heater/air conditioning housing assembly
     
    Inside air temperature sensor duct from the heater/air conditioning housing assembly
     
    Passenger-s side SIR module electrical connector
     
    Passenger-s side SIR bracket and module assembly
     
    Instrument panel center support bracket.
     
    Electrical and vacuum connectors from the heater/air conditioning control head
     
    Knee bolster
     
    Driver-s floor hush panel
     
    Floor air outlet-to-heater/air conditioning housing assembly duct from the left side
     
    Passenger-s side floor hush panel
     
    Lower air floor air duct from the upper air duct from the right side
     
    Upper floor air duct from the heater/air conditioning housing from the right side
     
    Blower motor electrical connector
     
    Blower motor from the heater/air conditioning housing
     
    Temperature door and the vacuum solenoid electrical connectors, if equipped with the CJ2 air conditioning system
     
    Vacuum source line from the instrument panel harness connection
     
    Temperature door control motor electrical connector
     
    Rear floor air ducts from the heater/air conditioning housing from both side
     
    Heater/air conditioning housing-to-bulkhead/heater core module and instrument panel nuts/bolts
     
    Heater/air conditioning housing assembly
     
    Air inlet, drain and plumbing seals. Discard the seals
     
    Heater core cover from the heater/air conditioning housing assembly
     
    Heater core cover seals and discard the seals
     
    Outer heater core seal and discard the seal
     
    Heater core-to-heater/air conditioning housing mounting clip screws
     
    Heater core pipe screw
     
    Heater core

    Click image to see an enlarged view

    Fig. View of the heater/air conditioning housing assembly-Corvette

     

  8.  

To install:

  1. Install or connect the following:

    Heater core
     
    Heater core pipe screw
     
    Heater core-to-heater/air conditioning housing mounting clip screws
     
    New outer heater core seal, if equipped with the CJ2 air conditioning system
     
    New heater core cover seals
     
    Heater core cover to the heater/air conditioning housing assembly
     

  2.  
  3. Install the heater/air conditioning housing assembly by installing or connecting the following:

    New air inlet, drain and plumbing seals
     
    Heater/air conditioning housing assembly
     
    Heater/air conditioning housing-to-bulkhead/heater core module and instrument panel nuts/bolts
     
    Rear floor air ducts to the heater/air conditioning housing on both sides
     
    Temperature door control motor electrical connector
     
    Vacuum source line to the instrument panel harness connection
     
    Temperature door and the vacuum solenoid electrical connectors, if equipped with the CJ2 air conditioning system
     
    Blower motor to the heater/air conditioning housing
     
    Blower motor electrical connector
     
    Upper floor air duct to the heater/air conditioning housing on the right side
     
    Lower air floor air duct to the upper air duct on the right side
     
    Passenger-s side floor hush panel
     
    Floor air outlet-to-heater/air conditioning housing assembly duct on the left side
     
    Driver-s floor hush panel
     
    Knee bolster
     
    Electrical and vacuum connectors to the heater/air conditioning control head
     
    Instrument panel center support bracket
     
    Passenger-s side SIR bracket and module assembly
     
    Inside air temperature sensor duct
     
    Windshield defroster duct to the heater/air conditioning housing assembly
     
    DRL electrical connector and the sun load temperature sensor, if equipped with a windshield defroster duct
     
    Inboard side window glass defroster duct to the windshield defroster duct on both sides
     
    Electrical connector to the instrument cluster and install the instrument cluster
     
    Upper instrument pad and the ventilation duct assembly
     
    Drain tube to the heater/air conditioning housing assembly
     
    Refrigerant lines to the evaporator core
     
    Heater hoses to the heater core
     
    Intake manifold
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Evacuate, charge and leak test the air conditioning system refrigerant.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. If equipped, enable the SIR system by performing the following procedure:
    1. Connect the Connector Positive Assurance (CPA) to the yellow 2-way SIR harness connector at the base of the steering column.
    2.  
    3. Install the left side sound insulator.
    4.  
    5. Install the SIR fuse to the fuse panel.
    6.  

  12.  
  13. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  14.  


CAUTION
Some vehicles are equipped an SIR or air bag system. The air bag system must be disabled before performing service on or around the air bag, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary air bag system repairs.


CAUTION
The air bag system must be disabled before performing service on or around the air bag, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary air bag system repairs.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disable the SIR system by using the following procedure:
    1. Remove the SIR fuse from the fuse panel.
    2.  
    3. Remove the left side sound insulator.
    4.  
    5. Disconnect the Connector Positive Assurance (CPA) from the yellow 2-way SIR harness connector at the base of the steering column and separate the connector.
    6.  
    7. Disconnect the steering wheel module coil connector located at the base of the steering column.
    8.  
    9. Disconnect the CPA from the inflatable restraint instrument panel module connector located at the near the base of the steering column.
    10.  
    11. Disconnect the instrument panel module connector located near the base of the steering column.
    12.  
    13. Disconnect the negative battery cable.
    14.  

  4.  
  5. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Drain the cooling system into a clean container for reuse.
  8.  
  9. Remove or disconnect the following:

    Battery heat shield
     
    Intake manifold
     
    Hose from the right hand air injection check valve
     
    Bolt attaching the right hand air injection check valve to the cylinder head(s), if equipped
     
    Nut attaching the heater pipe bracket to the cowl and set the bracket aside
     
    Heater pipe-to-heater core bolt
     
    Heater pipe assembly from the core, allow any remaining coolant to drain and cap the lines. Discard the sealing washers.
     
    Accumulator hose-to-evaporator bolt
     
    Accumulator hose and evaporator tube from the evaporator. Discard the O-ring seals and cap hose and tube ends and also the evaporator.
     
    HVAC module drain tube from the module
     

  10.  
  11. Remove the following components to access the heater core assembly as follows:
    1. Remove the folding top stowage compartment lid extension by opening the compartment, removing the screws from the lower sides and the top of the panel. Lift the panel up off the bracket.
    2.  
    3. Open the console door.
    4.  
    5. Pull up on the rear of the traction control ride switch to release it from the retaining clips. If the switch will not release, carefully insert a suitable pry tool into the recess at the rear of the switch and carefully pull up at the rear of the switch.
    6.  
    7. Disconnect the connector from the traction switch.
    8.  
    9. Disconnect the LED connector from the harness connector and remove the switch.
    10.  
    11. Remove the console retaining nut covers using a suitable pry tool.
    12.  
    13. Remove the console retaining nuts.
    14.  
    15. Lift the rear of the console slightly and pull back gently to release the console from under the accessory trim plate.
    16.  
    17. Disconnect the accessory power plug connector, unscrew the plug housing retainer and remove the plug housing.
    18.  
    19. Disconnect the fuel door release electrical connector and if equipped, the rear lift window switch. Remove the switch.
    20.  
    21. Remove the console.
    22.  
    23. Apply the parking brake for additional clearance.
    24.  
    25. Place the transmission in second gear on models with an Automatic Transmission (AT) or fourth on models with a Manual Transmission (MT).
    26.  
    27. On models equipped with MT, grasp the shift control boot and apply light pressure in towards the shift lever to release the tabs from the IP accessory trim plate.
    28.  
    29. Release the remaining tabs using light pressure and remove the boot from the trim plate.
    30.  
    31. Remove the ashtray.
    32.  
    33. Remove the IP accessory trim plate grille.
    34.  
    35. Remove the accessory trim plate screws next to the cigar lighter and behind the ashtray.
    36.  
    37. Remove the accessory trim plate retaining screws in the grille opening.
    38.  
    39. Grasp the sides of the trim plate near the curve at the base.
    40.  
    41. Pull the trim plate rearwards to release the tabs, making sure to lift the rear of the trim plate to clear the driveline tunnel studs.
    42.  
    43. Disconnect the cigar lighter electrical connector.
    44.  
    45. Rotate the shift control boot and reposition one end down into the shifter opening in the trim plate, on models with MT.
    46.  
    47. Lift the trim plate over the shifter and boot and remove the trim plate.
    48.  
    49. Remove the fog lamp, rear compartment lid release switch.
    50.  
    51. Remove the driver knee bolster trim panel screw from behind the switch.
    52.  
    53. Remove the lower driver knee bolster screws,.
    54.  
    55. Grasp the knee bolster trim panel and pull firmly rearward to disengage the locking tabs. Disconnect the connector from the inside air temperature sensor and remove the panel.
    56.  
    57. Open the glove box and disconnect the light switch.
    58.  
    59. Remove the trim plugs from the bottom of the door by reaching behind the door and pushing the plugs out while using a pry tool on the front.
    60.  
    61. Remove the lower bolts and the upper and side screws.
    62.  
    63. Slide the glove box forward and unplug the wiring harness connector at the passenger side air bag.
    64.  
    65. Remove the glove box.
    66.  
    67. Remove the inboard side window glass defroster duct from the windshield defroster duct on both sides
    68.  
    69. Remove the DRL electrical connector and the sun load temperature sensor from the windshield defroster duct, if equipped
    70.  
    71. Remove the windshield side garnish moldings.
    72.  
    73. Remove the screws attaching the upper trim pad to the defroster duct.
    74.  
    75. Remove the screws attaching the upper trim pad to the left and right hand hinge pillars.
    76.  
    77. Remove the screws attaching the IP cluster bezel to the upper trim pad.
    78.  
    79. Remove the screws attaching the upper trim panel to the driver knee bolster outer bracket and center support bracket.
    80.  
    81. Remove the screw attaching the upper trim panel to the passenger SIR bracket.
    82.  
    83. Tilt the steering wheel to its lowest position.
    84.  
    85. Lift the rearward edge of the trim panel approximately 2 inches (5 CM) to provide clearance for the air distribution duct.
    86.  
    87. Slowly pull the pad away from the windshield while guiding the tabs past the hinge pillars.
    88.  
    89. Disconnect the remaining electrical connectors to the upper trim panel and remove the panel.
    90.  
    91. Remove the left hand side window defogger outlet duct.
    92.  
    93. Remove the inside air temperature sensor duct.
    94.  
    95. Disconnect the DRL sensor, if equipped.
    96.  
    97. Disconnect the left hand temperature sensor connector, if equipped.
    98.  
    99. Turn the key to the ON position.
    100.  
    101. Using a suitable pry tool, depress the park/lock cable retaining tab located on the underside of the ignition switch and pull to release the cable from the ignition switch.
    102.  
    103. Using a suitable pry tool, release the tab retaining the park/lock cable to the slot in the shift control cable.
    104.  
    105. Lift the park lock cable from the slot.
    106.  
    107. Grasp the cable end and pull rearwards to unlock the cable from the shifter pivot arm stud.
    108.  
    109. Remove the park/lock cable.
    110.  
    111. Remove the CPA from the electrical connector on the inflatable restraint and Sensing and Diagnostic Module (SDM).
    112.  
    113. Disconnect the SDM.
    114.  
    115. Remove the ignition switch bolts and position the switch aside.
    116.  
    117. Mark the position of the IP center support bracket.
    118.  
    119. Remove the right bolt that attaches the bracket to the driveline tunnel.
    120.  
    121. Remove the bolts that attach the bracket to the passenger knee bolster bracket.
    122.  
    123. Remove the bolt that attaches the bracket to the IP lower support beam.
    124.  
    125. Remove the left bolt that attaches the bracket to the driveline tunnel.
    126.  
    127. Mark the location of the ignition switch bracket.
    128.  
    129. Remove the bolt that attaches the ignition switch housing bracket to the steering column bracket.
    130.  
    131. Remove the bolt that attaches the c enter support bracket to the IP lower support beam.
    132.  
    133. Pull the bracket away from the IP to access the radio control and HVAC connectors.
    134.  
    135. Disconnect connectors from the radio.
    136.  
    137. Disconnect the electrical connectors and vacuum harness connectors from the HVAC control.
    138.  
    139. Disconnect the IP wiring harness and parking brake connector clip from the bracket.
    140.  
    141. Remove the bolts attaching the ignition switch housing bracket to the center support bracket.
    142.  
    143. Note the routing of the IP wiring harness and remove the harness.
    144.  
    145. Remove the center bracket.
    146.  
    147. Remove the left hand floor outlet duct.
    148.  
    149. Remove the right hand side window defogger outlet duct.
    150.  
    151. Remove the SIR bracket and the passenger knee bolster bracket.
    152.  
    153. Disconnect the sunload electrical connector.
    154.  
    155. Disconnect the right hand temperature actuator electrical connector.
    156.  
    157. Remove the right hand floor air duct.
    158.  
    159. Move the carpet away from the right hand side of the driveline tunnel to remove the carpet air duct (rear).
    160.  
    161. Remove the right hand floor air duct (rear).
    162.  
    163. Disconnect the blower motor connector.
    164.  
    165. Remove the blower motor.
    166.  
    167. Disconnect the vacuum supply from the HVAC module.
    168.  
    169. Disconnect the vacuum solenoid connector.
    170.  
    171. Remove the windshield defroster duct.
    172.  
    173. Remove the HVAC module and discard seals.
    174.  
    175. Remove the heater core outlet cover screws and the cover.
    176.  
    177. Remove the heater core cover screws and the cover. Discard the heater core cover seals.
    178.  
    179. Remove and discard the heater core outer seal.
    180.  
    181. Remove the core clamp screw and clamp.
    182.  
    183. Remove the core pipe retaining clamp screw and remove the core from the case.
    184.  
    185. Remove and discard the core lower, center, upper and side seals.
    186.  
    187. Remove the core pipe clamp using a suitable tool.

      Click image to see an enlarged view

      Fig. View of the HVAC module housing assembly

    188.  

  12.  

To install:

  1. Install the core pipe clamp.
  2.  
  3. Install new core lower, center, upper and side seals.
  4.  
  5. Install the core in the case.
  6.  
  7. Install the core pipe retaining clamp and screw.
  8.  
  9. Install the core clamp and screw.
  10.  
  11. Install a new heater core outer seal.
  12.  
  13. Install new cavity seals.
  14.  
  15. Install the heater core cover and screws.
  16.  
  17. Install the heater core outlet cover and screws.
  18.  
  19. Install the HVAC module using new seals. Make sure the dashmat is aligned. The opening in the dashmat for the HVAC drain should be aligned so the drain opening in the cowl is approximately centered in the dashmat opening allowing room from the module drain seal to fully align against the cowl. Make sure the heater core joint fitting, condenser fitting module drain and module studs correspond with the openings in the cowl. Insert the left hand stud into the cowl first, then the module drain, then the right hand stud. Install the right hand then the left hand bolts and tighten to 89 inch lbs. (10 Nm).
  20.  
  21. Install the windshield defroster duct.
  22.  
  23. Connect the vacuum solenoid connector.
  24.  
  25. Connect the vacuum supply to the HVAC module.
  26.  
  27. Install the blower motor.
  28.  
  29. Connect the blower motor connector.
  30.  
  31. Install the right hand floor air duct (rear).
  32.  
  33. Install the carpet air duct (rear) and replace carpet.
  34.  
  35. Install the right hand floor air duct.
  36.  
  37. Connect the right hand temperature actuator electrical connector.
  38.  
  39. Connect the sunload electrical connector.
  40.  
  41. Install the SIR bracket and the passenger knee bolster bracket and tighten the bolts to 106 ft. lbs. (12 Nm).
  42.  
  43. Install the right hand side window defogger outlet duct.
  44.  
  45. Install the left hand floor outlet duct.
  46.  
  47. Position the ignition switch housing bracket to the center bracket aligning the marks made during removal, tighten the bolts to 106 inch lbs. (12 Nm).
  48.  
  49. Install the center bracket.
  50.  
  51. Rout the IP wiring harness. Connect the IP wiring harness and parking brake connector clip to the bracket.
  52.  
  53. Connect the electrical connectors and vacuum harness connectors from the HVAC control.
  54.  
  55. Connect connectors to the radio.
  56.  
  57. Install the center support bracket aligning the marks made during removal and tighten the left bolt that attaches the bracket to the IP lower support beam to 106 inch lbs. (12 Nm).
  58.  
  59. Install the ignition switch housing aligning the marks made during removal and tighten the bolt to 17 inch lbs. (2 Nm).
  60.  
  61. Install the left bolt that attaches the bracket to the driveline tunnel and tighten to 106 ft. lbs. (12 Nm).
  62.  
  63. Install the bolt that attaches the bracket to the IP lower support beam and tighten to 106 ft. lbs. (12 Nm).
  64.  
  65. Install the bolts that attach the bracket to the passenger knee bolster bracket and tighten to 106 ft. lbs. (12 Nm).
  66.  
  67. Install the right bolt that attaches the bracket to the driveline tunnel and tighten to 106 ft. lbs. (12 Nm).
  68.  
  69. Install the ignition switch.
  70.  
  71. Connect the SDM.
  72.  
  73. Install the CPA electrical.
  74.  
  75. Route the park/lock cable through the IP center support bracket. Make sure to route the cable under the wiring harness and over the floor rear outlet.
  76.  
  77. Engage the park/lock cable to the ignition switch.
  78.  
  79. Turn the ignition switch OFF.
  80.  
  81. Engage the park/lock cable to the shift control pivot arm stud once aligned pull back to lock.
  82.  
  83. Insert the cable into the slot on the shift control making sure it locks in place.
  84.  
  85. Turn the ignition ON.
  86.  
  87. Place the shift lever in each position but park and try to turn the key to the OFF position.
  88.  
  89. If the key turns to the OFF position except in park the cable is working properly.
  90.  
  91. Place the shift lever in PARK. Turn the key OFF and remove the key.
  92.  
  93. Install the trim panel and attach the hazard warning switch connector.
  94.  
  95. Install the upper trim panel.
  96.  
  97. Install the screws attaching the upper trim pad to the defroster duct.
  98.  
  99. Install the screws attaching the upper trim pad to the left and right hand hinge pillars.
  100.  
  101. Install the screws attaching the upper trim panel to the driver knee bolster outer bracket and center support bracket.
  102.  
  103. Install the screw attaching the upper trim panel to the passenger SIR bracket.
  104.  
  105. Install the screws attaching the IP cluster bezel to the upper trim pad.
  106.  
  107. Install the windshield side garnish moldings.
  108.  
  109. Install the DRL electrical connector and the sun load temperature sensor to the windshield defroster duct, if equipped
  110.  
  111. Install the inboard side window glass defroster duct to the windshield defroster duct on both sides
  112.  
  113. Connect the passenger side air bag connector and install the glove box.
  114.  
  115. Install the upper and side screws and tighten to 7 inch lbs. (2 Nm).
  116.  
  117. Install the lower retaining bolts and tighten to 106 inch lbs. (12 Nm). Install the trim plugs.
  118.  
  119. Connect the light switch and close the door.
  120.  
  121. Connect the inside air temperature switch connector and install the drivers knee bolster trim in position. Insert the connector for the fog lamp, rear compartment lid release switch through the opening in the panel.
  122.  
  123. Install the trim panel and tighten the screws to 16 inch lbs. (1.8 Nm).
  124.  
  125. Install the fog lamp, rear compartment lid release switch.
  126.  
  127. Lower the trim plate over the shifter and under the parking brake lever.
  128.  
  129. Place the shifter boot in position and insert a tool up through the shifter opening in the trim plate.
  130.  
  131. Connect the cigar lighter electrical connector.
  132.  
  133. Install the trim plate into position, install the upper locator tabs and upper locking tabs, then work downwards to engage the remaining tabs.
  134.  
  135. Install the trim plate screws and tighten to 17 inch lbs. (2 Nm).
  136.  
  137. Install trim plate grille.
  138.  
  139. Install the ashtray.
  140.  
  141. Install the shift boot in position and press to engage the tabs.
  142.  
  143. Place the transmission in Park on models with an Automatic Transmission (AT) or reverse on models with a Manual Transmission (MT).
  144.  
  145. Release the parking brake.
  146.  
  147. Install the console.
  148.  
  149. Install the fuel door release electrical switch and if equipped, the rear lift window switch and attach the connections.
  150.  
  151. Install the accessory power plug and attach connector.
  152.  
  153. Slide the console under the accessory trim plate.
  154.  
  155. Install the console retaining nuts.
  156.  
  157. Install the console retaining nut covers.
  158.  
  159. Install the traction switch.
  160.  
  161. Connect the LED connector to the harness connector.
  162.  
  163. Connect the traction switch connector.
  164.  
  165. Engage traction switch to the retaining clips.
  166.  
  167. Close the console door.
  168.  
  169. Install the stowage compartment and tighten the screws to 35 inch lbs. (4 Nm).
  170.  

  1. Install or connect the following:

    Battery heat shield
     
    Intake manifold
     
    Hose to the right hand air injection check valve
     
    Bolt attaching the right hand air injection check valve to the cylinder head(s), if equipped
     
    Heater pipe bracket to the cowl and tighten the bolt
     
    Heater pipe-to-heater core bolt
     
    Heater pipe assembly to the core.
     
    Accumulator hose-to-evaporator bolt
     
    Accumulator hose and evaporator tube to the evaporator using new O-ring seals.
     
    HVAC module drain tube to the module
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Evacuate, charge and leak test the air conditioning system refrigerant.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. If equipped, enable the SIR system by performing the following procedure:
    1. Connect the Connector Positive Assurance (CPA) to the yellow 2-way SIR harness connector at the base of the steering column.
    2.  
    3. Connect the steering wheel module coil connector located at the base of the steering column.
    4.  
    5. Connect the CPA from the inflatable restraint instrument panel module connector located at the near the base of the steering column.
    6.  
    7. Connect the instrument panel module connector located near the base of the steering column.
    8.  
    9. Install the left side sound insulator.
    10.  
    11. Install the SIR fuse to the fuse panel.
    12.  

  10.  
  11. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  12.  

 
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