G6 2005-2007

Removal & Installation

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  1. Place the front wheels in the straight ahead position.
  2.  
  3. Disable the air bag system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Disconnect the heater hoses at the heater core.
  10.  
  11. Recover the air conditioning refrigerant.
  12.  
  13. Remove the hose at the thermal expansion valve and plug the hose.
  14.  
  15. Disconnect the HVAC module to front of dash plate bolts.
  16.  
  17. Remove the right and left side console trim panels.
  18.  
  19. Remove the front floor console.
  20.  
  21. Remove the left closeout panel.
  22.  
  23. Remove both instrument panel outer trim panels.
  24.  
  25. Remove the instrument panel-to-body wire harness and antenna left connectors.
  26.  
  27. Remove the instrument panel-to-wire harness right side connectors.
  28.  
  29. Remove the knee bolster.
  30.  
  31. Remove the upper steering column trim cover.
  32.  
  33. On the back side of the steering wheel are 4 openings for removing the driver inflator module. Place the steering wheel so that 2 of the openings are on top.
  34.  
  35. Install Driver Air Bag Removal tool J-44298 into 2 of the holes so it is fully inserted.

    Click image to see an enlarged view

    Fig. Installing driver air bag removal tool-G6

  36.  
  37. Pull the handle toward the back of the steering wheel, releasing the 2 spring-loaded fasteners at the same time.
  38.  
  39. Turn the steering wheel and open the tool.
  40.  
  41. Place the tool and repeat the same steps for the other 2 openings.
  42.  
  43. Pull the driver inflator module gently away from the steering wheel.
  44.  
  45. Remove the connector position assurance (CPA) and the electrical connector for the driver inflator module.
  46.  
  47. Remove the horn grounded lead from the steering wheel.
  48.  
  49. Remove the inflatable restraint module.
  50.  
  51. Disconnect the steering wheel control electrical connector.
  52.  
  53. Remove the steering wheel nut.
  54.  
  55. Remove the steering wheel using a puller.
  56.  
  57. Remove the controls and the control harness from the steering wheel.
  58.  
  59. Remove the steering column trim covers.
  60.  
  61. Disconnect the restraint module coil connectors and remove the coil.
  62.  
  63. Remove the multifunction turn signal and housing.
  64.  
  65. Remove the steering column knee bolster.
  66.  
  67. Remove the steering column shaft pinch bolt from the intermediate steering shaft.
    NOTE
    Install tie straps between the rake bracket assembly and the neck of the assist mechanism housing to prevent jacket assembly pull-apart. The steering column rake lever MUST be in the LOCK (FULL UP) position during steering column removal and installation to ensure that the rake lever bracket remains rigid. Install a tie strap around the lever and the jacket assembly to keep the lever in the LOCK position. Do not bend the steering column energy absorbing straps located on the upper steering column mounting bracket.

  68.  
  69. Disconnect the steering column electrical connectors and open the steering column wire harness retainer clip.
  70.  
  71. Without disconnecting the adjustable brake pedal cable, remove the accelerator pedal.
  72.  
  73. Position the adjustable brake pedal cable aside.
  74.  
  75. Remove the accelerator pedal bracket from the cowl.
  76.  
  77. Remove the upper and lower steering column mounting bolts.
  78.  
  79. Remove the steering column.
  80.  
  81. Remove the brake pedal assembly.
  82.  
  83. Remove the body control module (BCM).
  84.  
  85. Remove the center support bracket floor bolts.
  86.  
  87. Remove the automatic transmission shifter assembly.
  88.  
  89. Remove both windshield pillar garnish moldings.
  90.  
  91. Remove the instrument panel upper trim panel.
  92.  
  93. Remove the instrument panel-to-body bolts on both sides.
  94.  
  95. Remove the right and left floor heater ducts at the center floor heater duct.
  96.  
  97. Remove the instrument panel.
  98.  
  99. Remove the recirculation actuator wire harness connector.
  100.  
  101. Remove the air temperature actuator wire harness connector.
  102.  
  103. Remove the mode actuator wire harness connector.
  104.  
  105. Remove the blower motor wire harness connector.
  106.  
  107. Remove the blower motor resistor wire harness connector.
  108.  
  109. Remove the left hand side window defogger outlet duct.
  110.  
  111. Remove the lower floor duct push-in fastener.
  112.  
  113. Remove the HVAC module assembly mounting bolts and the HVAC module.
  114.  
  115. Remove the upper and lower center floor air outlet ducts
  116.  
  117. Drill out the heater core cover heat stakes.
  118.  
  119. Remove the heater core cover.
  120.  
  121. Remove the heater core.

    Click image to see an enlarged view

    Fig. HVAC assembly mounting-G6



    Click image to see an enlarged view

    Fig. Heater core mounting-G6

  122.  

To install:

  1. Install the heater core.
  2.  
  3. Install the heater core cover.
  4.  
  5. Install the upper and lower center floor air outlet ducts.
  6.  
  7. Install the HVAC module and tighten the bolts to 44 inch lbs. (5 Nm).
  8.  
  9. Install the lower floor duct push-in fastener.
  10.  
  11. Install the left hand side window defogger outlet duct.
  12.  
  13. Install the blower motor resistor wire harness connector.
  14.  
  15. Install the blower motor wire harness connector.
  16.  
  17. Install the mode actuator wire harness connector.
  18.  
  19. Install the air temperature actuator wire harness connector.
  20.  
  21. Install the recirculation actuator wire harness connector.
  22.  
  23. Install a new HVAC module drain seal and dash seal.
  24.  
  25. Install the instrument panel assembly.
  26.  
  27. Install the left and right floor heater ducts at the center floor heater duct.
  28.  
  29. Install the instrument panel-to-body bolts on both sides and tighten to 19 ft. Lbs. (26 Nm).
  30.  
  31. Install the I/P upper trim panel.
  32.  
  33. Install both windshield pillar garnish moldings.
  34.  
  35. Install the shifter assembly on automatic transmissions.
  36.  
  37. Install the center support bracket floor bolts and tighten to 89 inch lbs. (10 Nm).
  38.  
  39. Install the BCM.
  40.  
  41. Install the brake pedal assembly.
  42.  
  43. Tighten the 3 brake pedal assembly to I/P carrier bolts to 18 ft. lbs. (25 Nm).
  44.  
  45. Install the 2 brake pedal assembly to cowl mounting nuts and tighten to 11 ft. lbs. (15 Nm).
  46.  
  47. Connect the brake pedal pushrod retaining clip, the wave washers and the brake booster pushrod to the brake pedal pin.
  48.  
  49. On electric power steering models, install the motor/module assembly to the steering column.
  50.  
  51. Position the steering column in the vehicle.
  52.  
  53. Slide the lower end of the steering column shaft into the intermediate steering shaft,
  54.  
  55. Loosely install the lower steering column mounting bolt . Loosely install the upper steering column mounting bolts.
    NOTE
    Do not bend the steering column energy absorbing straps located on the upper steering column mounting bracket during installation.

  56.  
  57. Align the energy absorbing straps with the bolt holes in the steering column. Loosely install the upper steering column bolts.
  58.  
  59. Tighten the steering column fasteners in the following sequence:
    1. Tighten the lower bolt to 18 ft. lbs. (25 Nm).
    2.  
    3. Tighten the left side upper bolt to 18 ft. lbs. (25 Nm).
    4.  
    5. Tighten the right side upper bolt to 18 ft. lbs. (25 Nm).
    6.  

  60.  
  61. Connect the steering column electrical connectors and close the wire harness retainer clip on the steering column.
  62.  
  63. Install the adjustable accelerator bracket to the vehicle.
  64.  
  65. Install the 3 adjustable accelerator bracket nuts and tighten to 89 inch lbs. (10 Nm).
    NOTE
    Ensure that the adjustable accelerator pedal and adjustable brake pedal are synchronized in the full rearward position.

  66.  
  67. Install a new adjustable brake pedal cable.
  68.  
  69. Install the accelerator pedal to the vehicle.
  70.  
  71. Install the steering column knee bolster.
  72.  
  73. Install the multifunction turn signal switch housing.
  74.  
  75. Install the multifunction turn signal.
  76.  
  77. Aim the wheels straight ahead.
  78.  
  79. Align the block tooth and the centering mark on the race and upper shaft assembly at the 12 o'clock position.
  80.  
  81. Slide the new SIR coil onto the steering shaft assembly.
  82.  
  83. Connect the SIR harness.
  84.  
  85. Remove and discard the centering tab from the new SIR coil.
  86.  
  87. Install the steering column trim covers.
  88.  
  89. Install the controls and the control harness to the steering wheel.
  90.  
  91. Route the steering column wiring through the steering wheel.
  92.  
  93. Install the steering wheel.
  94.  
  95. Connect the steering wheel control electrical connector.
  96.  
  97. Install the steering wheel nut and tighten to 24 ft. lbs. (32 Nm).
  98.  
  99. Connect the horn ground lead onto the steering wheel.
  100.  
  101. Connect the inflator module electrical connector and the CPA.
    NOTE
    This vehicle is equipped with dual stage frontal air bags. Match the right color connector to the right color opening in the module. Route the driver inflator wires, the redundant control wires, and the horn wires correctly.

  102.  
  103. Align the driver inflator module fasteners to the steering column fastener holes.
  104.  
  105. Push the driver inflator module firmly into the steering column in order to engage the fasteners.
  106.  
  107. Install the steering column trim covers.
  108.  
  109. Install the crush bracket to the front of dash plate nuts and tighten to 89 inch lbs. (10 Nm).
  110.  
  111. Install the steering column to the I/P wire harness connector.
  112.  
  113. Install the knee bolster.
  114.  
  115. Install the I/P to the body wire harness RH connectors.
  116.  
  117. Install the I/P to the body wire harness and antenna LH connectors.
  118.  
  119. Install both I/P outer trim panels.
  120.  
  121. Install the left closeout panel.
  122.  
  123. Install the console.
  124.  
  125. Install the left and right console trim panels
  126.  
  127. Install the right console trim panel.
  128.  
  129. Install the HVAC module to the MOD plate bolts and tighten to 35 inch lbs. (4 Nm).
  130.  
  131. Unplug the A/C components.
  132.  
  133. Install new sealing washers.
  134.  
  135. Install the liquid and suction lines at the TXV.
  136.  
  137. Evacuate and charge the refrigerant system.
  138.  
  139. Leak test the fittings.
  140.  
  141. Install the heater hoses at the heater core.
  142.  
  143. Fill the coolant.
  144.  
  145. Connect the negative battery cable.
  146.  
  147. Enable the SIR system.
  148.  
  149. Perform the power steering control module programming. See STEERING and SUSPERNSION.
  150.  
  151. Perform the brake pedal position sensor calibration. See BRAKES.
  152.  

 
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