Solstice 2006-2008, Sky 2007-2008

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disable the SIR system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the cooling system.
  8.  
  9. Recover the refrigerant.
  10.  
  11. Remove the A/C compressor tube assembly nut.
  12.  
  13. Remove the sealing washer.
  14.  
  15. Remove the thermal expansion valve bolt.
  16.  
  17. Remove the sealing washer.
  18.  
  19. Remove the evaporator tube from the thermal expansion valve.
  20.  
  21. Remove the air inlet grille panel.
  22.  
  23. Remove the heater inlet hose from the heater core.
  24.  
  25. Remove the heater outlet hose from the heater core.
  26.  
  27. Remove the shift knob, if equipped with a manual transmission.
  28.  
  29. Remove the console shift lever bezel, if equipped with an automatic transmission.
  30.  
  31. Remove the instrument panel assist handle.
  32.  
  33. Remove the instrument panel cluster (IPC) trim plate.
  34.  
  35. Remove the driver knee bolster trim panel.
  36.  
  37. Remove the instrument panel (I/P) compartment.
  38.  
  39. Disable the supplemental inflatable restraint (SIR) system Zone 5.
  40.  
  41. Remove the I/P inflatable restraint.
  42.  
  43. Remove the right and left I/P outer trim covers.
  44.  
  45. Remove the right and left windshield pillar garnish moldings.
  46.  
  47. Remove the I/P extension trim plate.
  48.  
  49. Remove the knee bolster panel.
  50.  
  51. Remove the knee bolster bracket.
  52.  
  53. Remove the steering column trim panels.
  54.  
  55. Disable the supplemental inflatable restraint (SIR) system Zone 3.
  56.  
  57. Insert a small flat bladed tool through the access openings, on the left and right of the steering wheel.
  58.  
  59. Push on the flat bladed tool to release the steering wheel inflator from the steering wheel.
  60.  
  61. Remove the steering wheel.
  62.  
  63. Lower and position the steering column out of the way.
  64.  
  65. Remove the instrument panel carrier bolt.
  66.  
  67. Remove the instrument panel carrier screw.
  68.  
  69. Remove the instrument panel carrier nut.
  70.  
  71. Remove the instrument panel carrier assembly.
    NOTE
    Note the routing of the I/P wiring harness around the I/P tie bar to aid in the reinstallation procedure

  72.  
  73. Remove the nuts securing the air distribution duct to the I/P tie bar.
  74.  
  75. Remove the bolts securing the I/P tie bar to the brake pedal bracket.
  76.  
  77. Disconnect the HVAC module assembly electrical connectors.
  78.  
  79. Disconnect the actuator electrical connectors from the recirculation case.
  80.  
  81. Remove the air outlet duct screw.
  82.  
  83. Remove the air outlet duct.
  84.  
  85. Remove the heater core cover screw.
  86.  
  87. Remove the heater core cover.
  88.  
  89. Remove the heater core pass-through seal.
  90.  
  91. Remove the air distribution case screw.
  92.  
  93. Remove the air distribution case.
  94.  
  95. Remove the heater core.

    Click image to see an enlarged view

    Fig. IP tie bar



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    Fig. IP carrier



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    Fig. Steering wheel inflator module



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    Fig. IP inflator module



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    Fig. Thermal expansion valve



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    Fig. HVAC unit



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    Fig. Heater core removal

  96.  

To install:

  1. Installation is the reverse of removal procedure.
  2.  
  3. Please take note of the following tightening specifications:

    HVAC module nuts: 89 inch. lbs. (10 Nm)
     
    A/C compressor tube nut: 12 ft. lbs. (16 Nm)
     
    Thermal expansion valve bolt: 12 ft. lbs. (16 Nm)
     
    IP tie bar bolts: (1) 18 ft. lbs. (25 Nm)
     
    IP tie bar bolts: (2) 106 inch. lbs. (12 Nm)
     
    IP carrier fasteners: 80 inch. lbs. (9 Nm)
     

  4.  
  5. Replace all seals.
  6.  
  7. Evacuate and recharge A/C system.
  8.  
  9. Refill and bleed the cooling system.
  10.  
  11. Enable the SIR system.
  12.  
  13. Connect the negative battery cable.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disable the SIR system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the cooling system.
  8.  
  9. Recover the refrigerant.
  10.  
  11. Remove the thermal expansion valve nut.
  12.  
  13. Remove the evaporator tube from the thermal expansion valve. Remove and discard the sealing washer.
  14.  
  15. Remove the air inlet grille panel.
  16.  
  17. Remove the heater inlet hose from the heater core.
  18.  
  19. Remove the heater outlet hose from the heater core.
  20.  
  21. Remove the windshield garnish molding.
  22.  
  23. Remove the instrument panel outer trim covers.
  24.  
  25. Remove the instrument panel cluster housing.
  26.  
  27. Remove the knee bolster.
  28.  
  29. Remove the instrument panel accessory trim plate.
  30.  
  31. Remove the instrument panel compartment door frame.
  32.  
  33. Remove the instrument panel lower trim panel.
  34.  
  35. Remove the instrument panel inflatable restraint module.
  36.  
  37. Remove the instrument panel (I/P) upper trim panel.
  38.  
  39. Remove the I/P cluster.
  40.  
  41. Remove the radio.
  42.  
  43. Remove the HVAC control module.
  44.  
  45. Remove the bolts and nuts securing the column to the instrument panel, lower and position the steering column out of the way. Refer to steering column replacement.
  46.  
  47. Remove the instrument panel (I/P) carrier assembly.
  48.  
  49. Note the routing of the I/P wiring harness around the I/P tie bar to ensure the proper reinstallation.
  50.  
  51. Remove the nuts securing the air distribution duct to the I/P tie bar.
  52.  
  53. Remove the bolts securing the I/P tie bar to the brake pedal bracket.
  54.  
  55. Disconnect the HVAC module assembly electrical connectors.
  56.  
  57. Remove the air outlet duct screw.
  58.  
  59. Remove the air outlet duct.
  60.  
  61. Remove the heater core cover screw.
  62.  
  63. Remove the heater core cover.
  64.  
  65. Remove the heater core pass-through seal.
  66.  
  67. Remove the air distribution case screw.
  68.  
  69. Remove the air distribution case.
  70.  
  71. Remove the heater core.

    Click image to see an enlarged view

    Fig. Inflatable restraint instrument panel module



    Click image to see an enlarged view

    Fig. Instrument panel lower trim panel



    Click image to see an enlarged view

    Fig. Knee bolster



    Click image to see an enlarged view

    Fig. Saturn Sky instrument upper trim panel



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    Fig. Instrument panel carrier



    Click image to see an enlarged view

    Fig. Instrument panel tie bar



    Click image to see an enlarged view

    Fig. HVAC module assembly



    Click image to see an enlarged view

    Fig. Heater core and related parts

  72.  

To install:

  1. Installation is the reverse of removal procedure.
  2.  
  3. Please take note of the following tightening specifications:

    Tighten HVAC module nuts to 89 inch. lbs. (10 Nm)
     
    Thermal expansion valve nut: 12 ft. lbs. (16 Nm)
     
    Tighten instrument panel tie bar bolts, (1) to 18 ft. lbs. (25 Nm)
     
    Tighten instrument panel tie bar bolts, (2) to 106 inch. lbs. (12 Nm)
     
    Tighten instrument panel upper trim panel screws 12 ft. lbs. (16 Nm)
     
    Tighten instrument panel carrier fasteners to 80 inch. lbs. (9 Nm)
     
    Tighten knee bolster screws to 22 inch. lbs. (2.5 Nm).
     
    Tighten inflatable restraint instrument panel Module Bolts to 89 inch. lbs. (10 Nm).
     

  4.  
  5. Replace all seals.
  6.  
  7. Evacuate and recharge A/C system.
  8.  
  9. Refill and bleed the cooling system.
  10.  
  11. Enable the SIR system.
  12.  
  13. Connect the negative battery cable.
  14.  

 
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