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

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Heater hoses from the heater core
    NOTE
    Carefully, use compressed air to blow the remainder of the coolant from the heater core to prevent spillage of coolant in the interior when removing the heater core.

  10.  
  11. Remove or disconnect the following
    WARNING
    Be careful not to damage the heater duct-to-rear floor heater duct seal.



    Lower trim panel extensions (located at both sides of the console-to-center instrument panel), by pulling outward at the dual lock locations; then, rotate the panels outward to disengage the hinges at the console
     
    Lower instrument panel closeout panel (located on the right side of the heater/air conditioning housing), by pulling it out at the top edge and rotating the top downward
     
    Lower heater duct-to-heater/air conditioning housing 2 screws and 2 clips (located at the bottom of the heater/air conditioning housing); then, drop the duct down and carefully, slide it out sideways
     



    Release the retaining clip and disconnect the temperature control cable from the heater door hook
     
    Heater core side cover
     
    4 lower heater core cover-to-heater/air conditioning housing assembly screws and the cover
     
    Heater core clamp and the heater core

    Click image to see an enlarged view

    Fig. View of the lower trim panel extensions-S-Series



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater case-S-Series

     

  12.  

To install:

  1. Install or connect the following:
    WARNING
    Be careful not to damage the heater duct-to-rear floor heater duct seal



    Heater core, the clamp and the heater core-to-heater/air conditioning housing assembly screw
     
    Lower heater core cover and the 4 cover-to-heater/air conditioning housing assembly screws
     
    Heater core side cover and the cover screw, located at the left side of the heater/air conditioning housing assembly
     
    Temperature control cable to the heater door hook and secure with the retaining clip
     



    Lower heater duct; then, the lower heater duct-to-heater/air conditioning housing 2 screws and 2 clips, located at the bottom of the heater/air conditioning housing
     
    Lower instrument panel closeout panel, located at the right side of the heater/air conditioning housing
     
    Console-to-center instrument panel location (on both sides), install the lower trim panel extensions
     
    Heater hose-to-heater core clamps
     

  2.  
  3. Lower the vehicle.
  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Failure to use a drain hose will result in an uncontrolled coolant flow direction. Also a container capable of holding at least 8 quarts of coolant will be required.



    Negative battery cable
     
    Lower cradle splash shield-to-cradle and wheel house retainers
     
    Splash shield
     

  4.  
  5. Place a pliable piece of hose with an inside diameter of 3 / 8 inch over the radiator drain tube.
  6.  
  7. Route the hose rearward and downward and position it to drain the coolant into an approved container.
  8.  
  9. Using a flat bladed screwdriver to open the radiator drain valve and drain the coolant.
    NOTE
    Approximately 4 quarts of coolant can be drained from the radiator. More coolant will remain in the system. When completely drained, close the drain valve.

  10.  
  11. Slide the lower cradle splash shield between the wheelhouse linen and the wheelhouse. Install the fasteners and tighten to 44 inch lbs. (5 Nm).
  12.  
  13. Remove or disconnect the following:
    NOTE
    Carefully, use compressed air to blow the remainder of the coolant from the heater core to prevent spillage of coolant in the interior when removing the heater core.



    Heater inlet hose from the water pump outlet on 3.0L engines or thermostat on 2.2L engines
     
    Heater return hose from head bridge on 3.0L engines or block inlet on 2.2L engines
     



    Right console extension
     
    Heater core-to-pipe clamps
     
    Heater core from the end tank by gently pulling the pipes forward. Place rags on the floor to absorb any spilled coolant.
     
    Heater core screw and strap
     
    Heater core from module. The center console forward edge may need to be pulled outward to allow core removal.
     

  14.  

To install:

  1. Install or connect the following:

    Heater core into module, being careful not to damage the foam seals
     
    Heater core strap and screw and tighten the screw to 9 inch lbs. (1 Nm)
     
    New bushings and O-rings onto the core pipes
     
    Heater pipes to the core and install the plastic clamps. The clamps can only be installed one way, the lower clamp hinge fits into the tab of the core retaining strap
     
    Right console extension
     
    Heater inlet hose to the water pump outlet on 3.0L engines or thermostat on 2.2L engines
     
    Heater return hose to head bridge on 3.0L engines or block inlet on 2.2L engines
     

  2.  
  3. Rinse off any residual coolant.
  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Surge tank cap
     
    Water pump drain bolt and drain the coolant from the pump. Once drained, close the bolt and torque to 88 inch lbs. (10 Nm).
     
    Heater outlet and inlet hose clamps
     
    Heater outlet and inlet hoses
     

  4.  
  5. Remove the Body Control Module (BCM) as follows:
    1. Disconnect the negative battery cable.
    2.  
    3. Apply the parking brake and position the transmission into Neutral.
    4.  
    5. Remove the console shift lever bezel by lifting up around the edge carefully, if equipped with an automatic transmission.
    6.  
    7. Unsnap the shift boot from the console cup holder, if equipped with a manual transmission.
    8.  
    9. Lift the front console cup holder to disengage the retainers
    10.  
    11. Disconnect the cigar lighter connection.
    12.  
    13. Remove the cup holder, if equipped with a manual transmission, slide the boot through the cup holder.
    14.  
    15. Remove the console extension retainers from both sides by turning them counterclockwise.
    16.  
    17. Remove the console extensions by pulling the extension rearwards.
    18.  
    19. Remove the center extension screws, pull out the center extension to access any remaining fasteners and remove the extension.
    20.  
    21. Unsnap the parking brake boot.
    22.  
    23. If equipped with an armrest, remove the console compartment screws.
    24.  
    25. Lift up on the rear on the console to release the retainers.
    26.  
    27. Lift the console compartment and push the parking brake through the opening.
    28.  
    29. Slide the compartment over the parking brake lever.
    30.  
    31. Disconnect the rear power supply connector.
    32.  
    33. Remove the console screws and the console.
    34.  
    35. Remove the wiring harness rosebud from the right center support bracket.
    36.  
    37. Pull back the carpet from the right of the left Instrument Panel (IP) support bracket and remove the lower nuts.
    38.  
    39. Remove the center support bracket.
    40.  
    41. Disconnect the small then large harness connectors from the BCM.
    42.  
    43. Disconnect the small then large IP wiring harness connectors from the BCM.
    44.  
    45. Disconnect the Onstar®connector, if equipped.
    46.  
    47. Remove the BCM retainers and BCM.
    48.  

  6.  
  7. Remove or disconnect the following:

    Pull back the carpet at the bottom of the left IP support bracket
     
    Left IP support bracket nuts
     
    Accelerator pedal from the front of the dash and position aside
     
    Center floor outlet ducts by raising the duct and then pushing them to disengage them
     
    Rotate the center floor duct and pull down to disconnect it from the HVAC module
     
    Heater core cover screws
     
    Heater core cover down enough to clear the locating pins from the HVAC module, slide the cover rearwards until the drain tube clears the front of the dash. Slide the cover down, rearwards and to the right and remove it.
     
    Heater core
     

  8.  

To install:

  1. Inspect the heater core foam and if damaged use Kent Industries adhesive black foam 46480 to replace.
  2.  
  3. Install or connect the following:

    Heater core
     
    New drain tube seal on the drain tube
     

  4.  
  5. Spray the heater core seal and dashmat with soapy water to ease installation.

    Heater core cover from the right side. Slide the cover up, forward and into position. Align the drain tube with the hole in the dash, raise the cover into position while aligning the holes with the locating pins on the HVAC module. Tighten the cover screws to 15 inch lbs. (1.8 Nm).
     
    Center floor ducts.
     
    Accelerator pedal
     
    Carpet at the bottom of the left IP support bracket
     
    Left IP center bracket nuts and tighten to 88 inch lbs. (10 Nm)
     

  6.  
  7. Install the BCM as follows:
    1. Install the BCM and tighten the retainers to 88 inch lbs. (10 Nm).
    2.  
    3. Connect the small then large IP wiring harness connectors to the BCM.
    4.  
    5. Connect the small then large harness connectors to the BCM.
    6.  
    7. Connect the Onstar®connector, if equipped.
    8.  
    9. Pull back the carpet from the right of the left IP support bracket and the center support bracket. Tighten the nuts to 88 inch lbs. (10 Nm).
    10.  
    11. Connect the wiring harness rosebud to the right center support bracket.

      Install the front floor console over parking lever and shift lever. Push the console down on the carpet and tighten the screws to 22 inch lbs. (2.5 Nm).
       

    12.  
    13. Connect the rear power supply connector.
    14.  
    15. Slide the compartment over the parking brake lever.
    16.  
    17. Pull the parking brake boot through the opening.
    18.  
    19. Align the retainers with the console and push to engage.
    20.  
    21. If equipped with an armrest, install the console compartment screws and tighten the screws to 22 inch lbs. (2.5 Nm).
    22.  
    23. Snap the parking brake boot to the console.
    24.  
    25. Align the center extension to the IP and push the engage the retainers. Tighten the screws to 22 inch lbs. (2.5 Nm).
    26.  
    27. Install the cup holder, if equipped with a manual transmission, slide the boot through the cup holder.
    28.  
    29. Connect the cigar lighter connection.
    30.  
    31. Align the front console cup holder retainers and push to engage.
    32.  
    33. Snap the shift boot to the console cup holder, if equipped with a manual transmission.
    34.  
    35. Install the console shift lever bezel by aligning the fingers on the lever bezel with the slots on the lever base and push to engage, if equipped with an automatic transmission.
    36.  
    37. Apply the parking brake and position the transmission into park.
    38.  
    39. Install the console extensions. Turn the retainers clockwise to secure.
    40.  

  8.  
  9. Install or connect the following:

    Heater outlet and inlet hose clamps
     
    Heater outlet and inlet hoses
     
    Surge tank cap
     

  10.  
  11. Refill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  16.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Heater hoses from the heater core
    NOTE
    Carefully, use compressed air to blow the remainder of the coolant from the heater core to prevent spillage of coolant in the interior when removing the heater core.

  8.  
  9. Remove or disconnect the following
    WARNING
    Be careful not to damage the heater duct-to-rear floor heater duct seal.



    Lower trim panel extensions (located at both sides of the console-to-center instrument panel), by pulling outward at the dual lock locations; then, rotate the panels outward to disengage the hinges at the console
     
    Lower instrument panel closeout panel (located on the right side of the heater/air conditioning housing), by pulling it out at the top edge and rotating the top downward
     
    Lower heater duct-to-heater/air conditioning housing 2 screws and 2 clips (located at the bottom of the heater/air conditioning housing); then, drop the duct down and carefully, slide it out sideways
     



    Release the retaining clip and disconnect the temperature control cable from the heater door hook
     
    Heater core side cover
     
    4 lower heater core cover-to-heater/air conditioning housing assembly screws and the cover
     
    Heater core clamp and the heater core

    Click image to see an enlarged view

    Fig. View of the lower trim panel extensions-Saturn



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater case-Saturn

     

  10.  

To install:

  1. Install or connect the following:
    WARNING
    Be careful not to damage the heater duct-to-rear floor heater duct seal



    Heater core, the clamp and the heater core-to-heater/air conditioning housing assembly screw
     
    Lower heater core cover and the 4 cover-to-heater/air conditioning housing assembly screws
     
    Heater core side cover and the cover screw, located at the left side of the heater/air conditioning housing assembly
     
    Temperature control cable to the heater door hook and secure with the retaining clip
     



    Lower heater duct; then, the lower heater duct-to-heater/air conditioning housing 2 screws and 2 clips, located at the bottom of the heater/air conditioning housing
     
    Lower instrument panel closeout panel, located at the right side of the heater/air conditioning housing
     
    Console-to-center instrument panel location (on both sides), install the lower trim panel extensions
     
    Heater hose-to-heater core clamps
     

  2.  
  3. Lower the vehicle.
  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Surge tank cap
     
    Water pump drain bolt and drain the coolant from the pump. Once drained, close the bolt and torque to 88 inch lbs. (10 Nm).
     
    Heater outlet and inlet hose clamps
     
    Heater outlet and inlet hoses
     

  4.  
  5. Remove the Body Control Module (BCM) as follows:
    1. Disconnect the negative battery cable.
    2.  
    3. Apply the parking brake and position the transmission into Neutral.
    4.  
    5. Remove the console shift lever bezel by lifting up around the edge carefully, if equipped with an automatic transmission.
    6.  
    7. Unsnap the shift boot from the console cup holder, if equipped with a manual transmission.
    8.  
    9. Lift the front console cup holder to disengage the retainers
    10.  
    11. Disconnect the cigar lighter connection.
    12.  
    13. Remove the cup holder, if equipped with a manual transmission, slide the boot through the cup holder.
    14.  
    15. Remove the console extension retainers from both sides by turning them counterclockwise.
    16.  
    17. Remove the console extensions by pulling the extension rearwards.
    18.  
    19. Remove the center extension screws, pull out the center extension to access any remaining fasteners and remove the extension.
    20.  
    21. Unsnap the parking brake boot.
    22.  
    23. If equipped with an armrest, remove the console compartment screws.
    24.  
    25. Lift up on the rear on the console to release the retainers.
    26.  
    27. Lift the console compartment and push the parking brake through the opening.
    28.  
    29. Slide the compartment over the parking brake lever.
    30.  
    31. Disconnect the rear power supply connector.
    32.  
    33. Remove the console screws and the console.
    34.  
    35. Remove the wiring harness rosebud from the right center support bracket.
    36.  
    37. Pull back the carpet from the right of the left Instrument Panel (IP) support bracket and remove the lower nuts.
    38.  
    39. Remove the center support bracket.
    40.  
    41. Disconnect the small then large harness connectors from the BCM.
    42.  
    43. Disconnect the small then large IP wiring harness connectors from the BCM.
    44.  
    45. Disconnect the Onstar® connector, if equipped.
    46.  
    47. Remove the BCM retainers and BCM.
    48.  

  6.  
  7. Remove or disconnect the following:

    Pull back the carpet at the bottom of the left IP support bracket
     
    Left IP support bracket nuts
     
    Accelerator pedal from the front of the dash and position aside
     
    Center floor outlet ducts by raising the duct and then pushing them to disengage them
     
    Rotate the center floor duct and pull down to disconnect it from the HVAC module
     
    Heater core cover screws
     
    Heater core cover down enough to clear the locating pins from the HVAC module, slide the cover rearwards until the drain tube clears the front of the dash. Slide the cover down, rearwards and to the right and remove it.
     
    Heater core
     

  8.  

To install:

  1. Inspect the heater core foam and if damaged use Kent Industries adhesive black foam 46480 to replace.
  2.  
  3. Install or connect the following:

    Heater core
     
    New drain tube seal on the drain tube
     

  4.  
  5. Spray the heater core seal and dashmat with soapy water to ease installation.

    Heater core cover from the right side. Slide the cover up, forward and into position. Align the drain tube with the hole in the dash, raise the cover into position while aligning the holes with the locating pins on the HVAC module. Tighten the cover screws to 15 inch lbs. (1.8 Nm).
     
    Center floor ducts.
     
    Accelerator pedal
     
    Carpet at the bottom of the left IP support bracket
     
    Left IP center bracket nuts and tighten to 88 inch lbs. (10 Nm)
     

  6.  
  7. Install the BCM as follows:
    1. Install the BCM and tighten the retainers to 88 inch lbs. (10 Nm).
    2.  
    3. Connect the small then large IP wiring harness connectors to the BCM.
    4.  
    5. Connect the small then large harness connectors to the BCM.
    6.  
    7. Connect the Onstar® connector, if equipped.
    8.  
    9. Pull back the carpet from the right of the left IP support bracket and the center support bracket. Tighten the nuts to 88 inch lbs. (10 Nm).
    10.  
    11. Connect the wiring harness rosebud to the right center support bracket.

      Install the front floor console over parking lever and shift lever. Push the console down on the carpet and tighten the screws to 22 inch lbs. (2.5 Nm).
       

    12.  
    13. Connect the rear power supply connector.
    14.  
    15. Slide the compartment over the parking brake lever.
    16.  
    17. Pull the parking brake boot through the opening.
    18.  
    19. Align the retainers with the console and push to engage.
    20.  
    21. If equipped with an armrest, install the console compartment screws and tighten the screws to 22 inch lbs. (2.5 Nm).
    22.  
    23. Snap the parking brake boot to the console.
    24.  
    25. Align the center extension to the IP and push the engage the retainers. Tighten the screws to 22 inch lbs. (2.5 Nm).
    26.  
    27. Install the cup holder, if equipped with a manual transmission, slide the boot through the cup holder.
    28.  
    29. Connect the cigar lighter connection.
    30.  
    31. Align the front console cup holder retainers and push to engage.
    32.  
    33. Snap the shift boot to the console cup holder, if equipped with a manual transmission.
    34.  
    35. Install the console shift lever bezel by aligning the fingers on the lever bezel with the slots on the lever base and push to engage, if equipped with an automatic transmission.
    36.  
    37. Apply the parking brake and position the transmission into park.
    38.  
    39. Install the console extensions. Turn the retainers clockwise to secure.
    40.  

  8.  
  9. Install or connect the following:

    Heater outlet and inlet hose clamps
     
    Heater outlet and inlet hoses
     
    Surge tank cap
     

  10.  
  11. Refill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  16.  

 
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