Neon, 2000-2005

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. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Remove the instrument panel from the vehicle by removing or disconnecting the following:
    WARNING
    Lock the steering wheel in the straight-ahead position; this will prevent damage to the clockspring



    Push the seats back all the way
     
    Pry out the left and right A-pillar trim moldings and remove (using a trim stick tool)
     
    Upper instrument panel cover
     
    Pull up on the cluster bezel (carefully), and remove it from the vehicle
     
    Pull the instrument panel cover rearward (carefully), and remove it from the vehicle
     



    Steering column as an assembly
     
    Left and right instrument panel end caps
     
    Center console
     
    Depress the Data Link Connector (DLC) sides and remove the DLC from the instrument panel reinforcement
     
    4 bulkhead instrument panel screws
     
    2 brake pedal support bracket bolts
     
    2 center support mounting bolts
     
    Left and right A-pillar bolts; there are 2 on each side
     
    Antenna connector from the right side
     
    Left and right A-pillar door harness connectors
     
    2 HVAC wiring harness connectors from the top right of the instrument panel

    Click image to see an enlarged view

    Fig. Remove the right side upper instrument panel bezel

    Remove the right side upper instrument panel bezel

    Click image to see an enlarged view

    Fig. You must remove the instrument panel center vent duct

    You must remove the instrument panel center vent duct

    Click image to see an enlarged view

    Fig. The upper defrost duct is secured with retaining tabs

    The upper defrost duct is secured with retaining tabs

    Click image to see an enlarged view

    Fig. Remove the inner defrost duct

    Remove the inner defrost duct
     
    Left side wiring harness connector from the top left of the instrument panel for the vanity and rear view mirrors
     
    Pull off the HVAC control head knobs

    Click image to see an enlarged view

    Fig. Exploded view of the control panel retainer locations

    Exploded view of the control panel retainer locations
     
    2 top front center bezel screws
     
    Using a trim stick, carefully pry out the instrument panel center bezel and remove it
     
    2 HVAC control head screws
     
    Instrument panel wiring harness connector
     
    Vacuum harness connector
     

  8.  
  9. Pull the HVAC control head out of the instrument panel, twist it 90 degrees and push it back through the opening; do not disconnect the control cables.
  10.  
  11. Remove or disconnect the following:

    Air bag Control Module (ACM) from the center console
     
    Parking Brake Warning Lamp Switch from the center console
     
    Transmission Range Indicator Lamp from the center console
     

  12.  
  13. Using an assistant, pull the instrument panel rearward and remove it from the vehicle.
  14.  
  15. Drain the cooling system and remove the heater hoses at the firewall. Place plugs in the heater core outlets to prevent coolant spillage during the unit housing removal.
  16.  
  17. Remove the suction line at the expansion valve. Place a piece of tape over the open refrigerant line to prevent moisture and/or dirt from entering the line.
  18.  
  19. Remove the expansion valve from the evaporator fitting to prevent moisture and/or dirt from entering the evaporator.
  20.  
  21. Remove or disconnect the following:

    Rubber drain tube extension from the condensation drain tube
     
    Vacuum harness from the power brake booster (if equipped)
     
    Defroster duct
     
    3 retaining nuts located in the engine compartment, on the firewall

    Click image to see an enlarged view

    Fig. Location of the 3 firewall retaining studs

    Location of the 3 firewall retaining studs
     
    Right side retaining screw

    Click image to see an enlarged view

    Fig. Unit housing retaining screw location

    Unit housing retaining screw location
     
    Remaining nut located on the firewall stud

    Click image to see an enlarged view

    Fig. You must remove the retainers, then separate the air distribution module from the evaporator/blower module

    You must remove the retainers, then separate the air distribution module from the evaporator/blower module
     
    Blue 5-way wiring harness connector from the plenum
     
    Heater/air conditioning assembly from the vehicle
     
    Separate the air distribution outlet-to-parting case line foam seals

    Click image to see an enlarged view

    Fig. Remove the upper-to-lower housing retaining clips and screws

    Remove the upper-to-lower housing retaining clips and screws

    Click image to see an enlarged view

    Fig. Then separate the 2 halves of the module

    Then separate the 2 halves of the module

    Click image to see an enlarged view

    Fig. Remove the heater core from the case

    Remove the heater core from the case
     
    Evaporator lines and heater core tubes foam seals
     
    Clips and screws that hold the unit to the housing
     
    4 retaining screws from the inlet air duct on the module
     
    Air inlet and recirc door assembly from the module
     
    Sensing switch from its harness
     
    Upper-to-lower case retaining clips and screws
     
    Separate the case halves, and remove the evaporator
     
    Heater core

    Click image to see an enlarged view

    Fig. The blower motor assembly is located under the passenger-s side dash panel

    The blower motor assembly is located under the passenger-s side dash panel

    Click image to see an enlarged view

    Fig. Blower motor mounting and location of the retaining screws and wiring vehicles with air conditioning

    Blower motor mounting and location of the retaining screws and wiring vehicles with air conditioning

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel

    Exploded view of the instrument panel

    Click image to see an enlarged view

    Fig. Sectional view of the heater/air conditioning assembly

    Sectional view of the heater/air conditioning assembly

    Click image to see an enlarged view

    Fig. Exploded view of the expansion valve

    Exploded view of the expansion valve

    Click image to see an enlarged view

    Fig. View of the heater hoses and clamps

    View of the heater hoses and clamps
     

  22.  

To install:

  1. Install or connect the following:

    Heater core into the heater/air conditioning unit.
     
    Evaporator and the upper-to-lower case retaining clips and screws
     
    Sensing switch to its harness
     
    Recirc door assembly to the module and the air inlet
     
    Clips and screws that hold the unit to the housing
     
    Evaporator lines and heater core tubes foam seals.
     
    Air distribution outlet-to-parting case line foam seals
     
    Assembly into the vehicle
     
    Blue 5-way wiring harness connector to the plenum
     
    Nut on the dash panel stud
     
    Right side retaining screw
     
    3 retaining nuts located in the engine compartment, on the dash panel
     
    Defroster duct
     
    If equipped, the vacuum harness to the power brake booster
     
    Rubber drain tube extension to the condensation drain tube
     
    Expansion valve to the evaporator fitting
     
    Suction line at the expansion valve
     

  2.  
  3. Evacuate, charge and leak-test the air conditioning system, if equipped.
  4.  
  5. Install the heater hoses.
  6.  
  7. Refill the cooling system.
  8.  
  9. Install the instrument panel to the vehicle by performing the following procedure:

    Air bag Control Module (ACM)
     
    Parking Brake Warning Lamp Switch
     
    Transmission Range Indicator Lamp
     
    HVAC control head into the instrument panel
     
    Vacuum harness connector
     
    Instrument panel wiring harness connector
     
    2 HVAC control head screws
     
    Instrument panel center bezel
     
    2 top front center bezel screws
     
    HVAC control head knobs
     
    Left side wiring harness connector to the top left of the instrument panel for the vanity and rear view mirrors
     
    2 HVAC wiring harness connectors to the top right of the instrument panel
     
    Left and right A-pillar door harness connectors
     
    Antenna connector to the right side
     
    Left and right A-pillar bolts; there are 2 on each side
     
    2 center support mounting bolts
     
    2 brake pedal support bracket bolts
     
    4 bulkhead instrument panel screws
     
    Data Link Connector (DLC) to the instrument panel reinforcement
     
    Center console
     
    Left and right instrument panel end caps
     
    Steering column as an assembly
     
    Instrument panel cover
     
    Cluster bezel
     
    Upper instrument panel cover
     
    Left and right A-pillar trim moldings
     
    Move seats forward
     
    Negative battery cable
     

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

 
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