ION, L-Series, S-Series 1999-2005

Removal & Installation

Print

  1. Loosen the upper trim panel:
  2.  
  3. Remove the screws located under the upper trim panel on the passenger's side of the vehicle.
    NOTE
    Be careful not to damage the VIN plate when removing or replacing the upper trim panel.

  4.  
  5. Disengage the clips at the locations by grasping the edges of the upper trim panel and lifting up.
  6.  
  7. Loosing the steering column filler panel screws.
    NOTE
    Do not remove weatherstrips. Adhesion will be lost if removed.

  8.  
  9. Remove the left endcap assembly:
  10.  
  11. Carefully disengage the clips at the instrument panel (I/P) retainer assembly locations. Use of a blunt tool will aid in disengaging the clips.
  12.  
  13. Maneuver the assemblies past the inner I/P retainer assembly and the weatherstrips.
  14.  
  15. Gently pry the edges of the ignition lock bezel with a blunt tool and separate it from the lower shroud.
  16.  
  17. Remove the screws from the lower steering column shroud.
  18.  
  19. Lower the steering column by pushing down on the steering column adjusting handle.
  20.  
  21. Lift and remove the upper shroud from the steering column.
  22.  
  23. Remove the I/P bezel:
  24.  
  25. Disengage the clips from the retainer assembly by grasping the edges of the bezel near the clip location and pull outward.
  26.  
  27. Depress the wiring harness connector tabs and remove the harness from the dimmer/traction control switch assembly.
  28.  
  29. Remove the radio:
  30.  
  31. Pull the radio out slightly to access the rear of the radio.
  32.  
  33. Disconnect the electrical connector, antenna, and ground strap connector.
  34.  
  35. Remove the HVAC controller:
  36.  
  37. Disconnect the HVAC blower switch connector.
  38.  
  39. Disconnect the HVAC control head connector.
  40.  
  41. Remove the temperature cable by squeezing the lock tabs together while pulling the cable, coiled end, straight up beyond the retaining tabs.
  42.  
  43. Remove the mode cable by squeezing the lock tabs together while pulling the cable, coiled end, straight up beyond the retaining tabs.
  44.  

To install:


NOTE
Ensure the wiring harnesses do not interfere with the control lever movement.

  1. Cable Identification: Temperature Cable is white and Mode Cable is black
  2.  
  3. Install the HVAC controller:
  4.  
  5. Install the mode valve cable onto mode valve pin.
  6.  
  7. Snap the slot on the cable into the HVAC controller base.
  8.  
  9. Repeat the steps for the temperature cable.
  10.  
  11. Install the blower switch connector.
  12.  
  13. Install the HVAC controller connector, and tighten the HVAC controller-to-I/P retainer 22 inch lbs.(2.5 Nm).
  14.  
  15. Install the radio: Connect the wiring harnesses, connect the ground strap, and connect the antenna lead. Tighten the radio-to-I/P retainer 22 inch lbs.(2.5 Nm).
  16.  
  17. Install the I/P cluster bezel:
  18.  
  19. Connect the dimmer/traction control switch wiring harnesses.
  20.  
  21. Position the I/P cluster bezel by lining up the clip location.
  22.  
  23. Snap the I/P cluster bezel in place by pushing at the clip locations.
  24.  
  25. Position the upper steering column shroud.
  26.  
  27. Position the lower steering column shroud and the install screws.
  28.  
  29. Tighten the steering column shroud fasteners 13 inch lbs.(1.5 Nm).
  30.  
  31. Install the ignition bezel.
  32.  
  33. Align the peg of the ignition bezel with the cut-out in the lower shroud.
    NOTE
    Ensure that the endcap bottom portion is inside of the filler panel assembly.

  34.  
  35. Install the left endcap assembly:
  36.  
  37. Maneuver the assembly past the inner I/P retainer assembly and the weatherstrips.
  38.  
  39. Snap the clips into the I/P retainer assembly locations. Tighten the I/P endcap retaining screws 22 inch lbs.(2.5 Nm).
  40.  
  41. Install the steering column filler panel screws, and tighten the steering column filler panel fasteners 22 inch lbs.(2.5 Nm).
    NOTE
    Be careful not to damage the VIN plate when removing or replacing the upper trim panel.


    NOTE
    Ensure that the upper trim panel seal is correctly seated on the forward edge before installing the upper trim panel.

  42.  
  43. Install the I/P upper trim panel:
  44.  
  45. Ensure that the hook-and-loop fasteners on the upper trim panel are correctly inserted.
  46.  
  47. Position the upper trim panel on the retainer assembly.
  48.  
  49. Align the tabs on he sides of the upper trim panel with the openings in the windshield garnish molding.
  50.  
  51. Align the clips and the clip location.
  52.  
  53. Firmly snap in the clips at the clip locations.
  54.  
  55. Install the screws on the underside of the upper trim panel on the passenger's side of the vehicle, and tighten the I/P upper trim panel fastener 53 inch lbs.(6 Nm).
  56.  

  1. Remove the radio bezel trim plate.
  2.  
  3. Remove the radio mounting screws.
  4.  
  5. Disconnect the radio electrical and antenna connectors.
  6.  
  7. Remove the radio.
  8.  
  9. Remove the HVAC control assembly to I/P screws.
  10.  
  11. Rotate the front of the HVAC control assembly upward and toward the front of vehicle to gain access to the bottom of the HVAC control assembly.
  12.  
  13. Disconnect the electrical connectors from the HVAC control assembly.
  14.  
  15. Rotate the temperature knob to the full hot position.
  16.  
  17. Rotate the HVAC control assembly downward and release the temperature cable flag by pushing the tab forward and pushing down on the cable at the same time.
  18.  
  19. Remove the temperature cable eyelet from the drive pin by squeezing the drive pin together.
  20.  

To install:

  1. Rotate the temperature knob to the full hot position.
  2.  
  3. Install the cable eyelet onto the HVAC control assembly pin and install the cable housing flag into the slot in the HVAC control assembly until it engages the locking tab.
  4.  
  5. Connect the electrical connectors to the HVAC control assembly.
  6.  
  7. Install the screws that secure the HVAC control assembly to the I/P, and tighten the screws to 22 inch lbs.(2.5 Nm).
  8.  
  9. Connect the radio electrical and antenna connectors.
  10.  
  11. Install the radio mounting screws, and tighten the screws to 22 inch lbs.(2.5 Nm).
  12.  
  13. Install the radio trim bezel.
  14.  

  1. Pull out on the accessory trim plate in order to release the retaining fasteners.
  2.  
  3. Disconnect the accessory trim plate electrical connector(s).
  4.  
  5. Remove the screws from the radio and pull the radio out.
  6.  
  7. Disconnect the radio electrical connectors and remove the radio.
    NOTE
    Do not bend the mode and temperature cables.

  8.  
  9. Disconnect the mode and temperature cables from the HVAC control assembly.
  10.  
  11. Disconnect the HVAC control assembly electrical connectors.
  12.  
  13. Remove the HVAC control assembly screws and remove the HVAC control assembly.
  14.  

To install:

  1. Install the HVAC control assembly.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2.  
  3. Install the HVAC control screws, and tighten the screws to 22 inch lbs.(2.5 Nm).
    NOTE
    Do not bend the mode and temperature cables.

  4.  
  5. Connect the mode and temperature cables to the HVAC control assembly.
  6.  
  7. Connect the HVAC control assembly electrical connectors.
  8.  
  9. Place the radio in the vehicle and connect the radio electrical connectors.
  10.  
  11. Push the radio into position.
  12.  
  13. Install the radio screws, and tighten the screws to 22 inch lbs.(2.5 Nm).
  14.  
  15. Connect the accessory trim plate electrical connector(s).
  16.  
  17. Align the retaining fasteners with the I/P.
  18.  
  19. Push on the outer edge of the accessory trim plate in order to secure the retaining fasteners.
  20.  

  1. Pull out on the accessory trim plate in order to release the retaining fasteners.
  2.  
  3. Disconnect the accessory trim plate electrical connector(s).
  4.  
  5. Remove the screws from the radio and pull the radio out.
  6.  
  7. Disconnect the radio electrical connectors and remove the radio.
    NOTE
    Do not bend the mode and temperature cables.

  8.  
  9. Disconnect the mode and temperature cables from the HVAC control assembly.
  10.  
  11. Disconnect the HVAC control assembly electrical connectors.
  12.  
  13. Remove the HVAC control assembly screws and remove the HVAC control assembly.
  14.  

To install:

  1. Install the HVAC control assembly.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2.  
  3. Install the HVAC control screws, and tighten the screws to 22 inch lbs. (2.5 Nm).
    NOTE
    Do not bend the mode and temperature cables.

  4.  
  5. Connect the mode and temperature cables to the HVAC control assembly.
  6.  
  7. Connect the HVAC control assembly electrical connectors.
  8.  
  9. Place the radio in the vehicle and connect the radio electrical connectors.
  10.  
  11. Push the radio into position.
  12.  
  13. Install the radio screws, and tighten the screws to 22 inch lbs. (2.5 Nm).
  14.  
  15. Connect the accessory trim plate electrical connector(s).
  16.  
  17. Align the retaining fasteners with the I/P.
  18.  
  19. Push on the outer edge of the accessory trim plate in order to secure the retaining fasteners.
  20.  

 
label.common.footer.alt.autozoneLogo