Contents: Dismantling ⇩ Assembly ⇩
This procedure shows how to move the control panel to gain access for other work. The control panel is released on the passenger side and swung out of the way to gain access. The main wiring harnesses remain attached to the control panel.
Before disconnecting the battery, make sure that all requirements and conditions contained in the section on disconnecting the battery are met.
GENERAL INFORMATION, Precautions when working with electrical equipment.
Dismantling
1. Follow all safety rules when working with passive safety systems.
GENERAL INFORMATION, Safety precautions when working with the airbag system (SRS).
2. Drain the coolant from the cooling system.
COOLING SYSTEM: Td6, ADJUSTMENTS AND MAINTENANCE, Draining the coolant, flushing the system and filling.
3. Drain the air conditioning system and collect the refrigerant.
AIR CONDITIONING SYSTEM, AIR CONDITIONER DRAINING, REFRIGERANT RECOVERY AND CHARGING, Air conditioner draining - refrigerant recovery and refilling.
4. Remove the air intake box.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
5. Remove the front seats.
SEATS, REPAIR WORK, Front seat.
6. Remove the heater control unit.
HEATING AND VENTILATION, REPAIR WORK, Controls - heater (electronic control unit) (ECU).
7. Remove the air suspension control panel.
CAR INTERIOR PARTS, REPAIR WORK, Switch panel - air suspension.
8. Remove the parking brake lever assembly.
BRAKE SYSTEM, REPAIR WORK, Lever assembly - parking brake.
9. Remove the lower control panel shields.
CAR INTERIOR PARTS, REPAIR WORK, Side panel - center console.
10. Loosen and remove the HEVAC unit air ducts.
11. For left-hand drive vehicles: Remove the driver's left footrest.
CAR INTERIOR PARTS, REPAIR WORK, Footrest frame - left-hand steering wheel.
12. Install the lower trim of the "A" pillar.
CAR INTERIOR PARTS, REPAIR WORK, Trim - pillar "A" - lower.
13. Remove the upper A-pillar trims.
CAR INTERIOR PARTS, REPAIR WORK, Trim - pillar "A" - upper.
14. Remove the upper instrument panel trim on the driver's side.
CAR INTERIOR PARTS, REPAIR WORK, Upper control panel trim - driver's side.
15. Remove the upper instrument panel trim on the passenger side.
CAR INTERIOR PARTS, REPAIR WORK, Upper control panel trim - passenger side.
16. Remove the automatic transmission selector assembly.
AUTOMATIC TRANSMISSION - GM 5L40-E, REPAIR WORK, Selector lever - gear selector assembly.
17. Unscrew the 4 nuts securing the selector support and remove the selector support.
18. Cover any protruding parts to avoid damaging the control panel when removing it.
19. Remove the 4 screws securing the parking brake bracket to the body and remove the bracket.
20. Remove the 4 screws securing the center console support to the body and remove the support.
21. Having marked the fixed position, remove the Torx screw of the clamp connecting the lower and intermediate steering shafts of the steering column.
22. Unscrew the 2 steering shaft support mounting nuts, separate the support from the body and disconnect the steering shafts.
23. Having marked the fixed position, unscrew the nut and disconnect the rod from the windshield wiper motor.
24. Remove the 3 screws securing the windshield wiper drive, remove the drive with the electric motor and move it to the side for access.
25. Remove the 2 screws securing the control panel to the engine compartment bulkhead.
26. Remove the 2 Allen screws securing the air conditioner pipes to the bulkhead, disconnect the pipes, remove and discard the sealing rings.
CAUTION: Immediately cap all openings to prevent dirt and moisture from entering the system.
27. Install a container to collect the leaking coolant.
28. Loosen the clamps and remove the heating system hoses from the connecting plate on the body bulkhead.
29. Unscrew the 3 nuts securing the heater unit to the bulkhead.
30. Unscrew the 4 nuts and 2 screws securing the control panel to the body.
31. Cover the lower control panel brackets so as not to damage the carpeted floor.
32. Disconnect the 2 connector blocks and release the cable harness retainer from the "A" pillar near the lower edge of the windshield. Repeat the operation on the other side of the control panel. Tape the disconnected cables to the windshield.
33. Move the control panel far enough to allow the airbag connectors to be disconnected at the A-pillar.
34. Front passenger side only: Release the 2 additional cable harness retaining clips on the A-pillar.
35. Remove the transfer case electronic control unit.
TRANSFER CASE, REPAIR WORK, Electronic control unit - transfer case.
36. Disconnect the positive cable from the fuse box under the dashboard.
37. Disconnect the relay and connector from the fuse box under the dashboard.
38. Release the cable harness from the partition and move it to the side.
39. Disconnect the 2 connectors from the fuel pre-heater connector, if installed.
40. Disconnect the cable from the side turn signal repeater, release the rubber bushing of the inner wing and pull out the cable.
41. Remove both wheel arch liners.
EXTERIOR PARTS, REPAIR WORK, Mudguard - front wheel arch.
42. Release the wiring harness from the clips on the inner wing.
43. Remove the 10 Allen screws securing the electronics compartment cover and remove the cover.
44. Remove the 2 screws securing the electronic unit compartment in the engine compartment and move it to the side for access.
45. Loosen and remove the air intake duct from the inner wing.
46. Loosen the nuts and disconnect the ground terminals of the cable harness.
47. Remove the front bumper.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly.
48. Disconnect the hose from the rear window washer pump.
49. Release the 4 flexible fasteners securing the washer hose to the bumper beam and move the hose to the side.
50. Disconnect the horn connector.
51. Remove the turn signal lamp.
LIGHTING, REPAIR WORK, Front combination light - side light and direction indicator.
52. Disconnect the headlight connector.
53. Mark the position of the vertical body position sensor cable clamps, remove the clamps and disconnect the connector block.
54. Disconnect the connector blocks from the radiator block.
55. Disconnect the connector from the ABS sensor.
56. Disconnect the connector block from the air conditioner switch.
57. Disconnect the connector block from the air conditioning compressor.
58. Remove the steering angle sensor connector block.
59. Loosen the screw securing the lighting control module to the "A" pillar.
60. Move the lighting control module to the side.
61. Remove the screw securing the door harness connector block to the A-pillar and disconnect the connector block.
62. Loosen the nut securing the ground terminal to the A-pillar and remove the terminal.
63. Lift the carpet and remove the 3 fasteners securing the cable harness protective screen to the body, release and remove the screen.
64. Release the connector retaining clip from the body control unit (BSU) bracket.
65. Remove the 2 nuts and move the body control unit (BCU) to the side.
66. Release the main cable harness from the channel and lay the carpet in place.
67. With the help of an assistant, pull the harness out through the engine compartment bulkhead and rotate the control panel assembly for access when performing other work.
CAUTION: Make sure that the evaporator pipes are not damaged when moving the control panel.
68. Prop the control panel on a suitable stand to avoid damaging the floor carpet and decorative parts.
Assembly
1. With the help of an assistant, position the cable harnesses and control panel on the engine compartment bulkhead.
2. Connect the airbag and A-pillar connector blocks.
3. Lift the carpet, lay the cable harness, install the protective screen and secure it with clamps.
4. Lay and secure the carpet.
5. Install and secure the BCU computer bracket.
6. Install and secure the ground terminal to the A-pillar.
7. Connect the door harness connector block and secure it with the screw.
8. Install and secure the lighting control module.
9. Route the cable harness, connect the connectors to the radiator unit, air conditioner switch, compressor, ABS sensor and V-belt sensor. Check that the V-belt sensor cable and cable clamps are properly secured.
10. Connect the connector to the steering angle sensor connector.
11. Connect the horn and headlight connector blocks.
12. Install the front combination parking light and turn signal lamp.
LIGHTING, REPAIR WORK, Front combination light - side light and direction indicator.
13. Connect the rear window washer hose.
14. Position the washer hose on the bumper beam and secure it with flexible clamps.
15. Reinstall the front bumper.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly.
16. Install the electronic unit bracket in place and tighten the mounting bolts to a torque of 3 Nm.
17. Install the electronics compartment cover, tighten the Allen screws and tighten them to 2 N·m.
18. Secure the cable harness to the inner fender.
19. Install and secure both wheel arch liners.
EXTERIOR PARTS, REPAIR WORK, Mudguard - front wheel arch.
20. Route the cable, install and secure the turn signal repeater lamp.
21. Position the cable, install and secure the liquid fuel heater connector block.
22. Connect the relay to the fuse box under the dashboard.
23. Connect the "positive" cable to the fuse box under the dashboard.
24. Install the transfer case electronic control unit.
TRANSFER CASE, REPAIR WORK, Electronic control unit - transfer case.
25. Install the control panel on the engine compartment bulkhead, tighten the nuts and screws and tighten them to a torque of 25 N·m.
26. Secure the cable harness with clamps on the A-pillar.
27. Install the HEVAC unit mounting nuts to the engine compartment bulkhead and tighten them to 10 N·m.
28. Connect the cooling system hoses and secure them with clamps.
29. Lubricate new sealing rings with clean special oil and install them on the pipes and hoses.
30. Position the air conditioning pipes on the bulkhead, tighten the mounting screws and tighten them to 25 Nm.
31. Tighten the screws securing the control panel to the engine compartment bulkhead to a torque of 25 N·m.
32. Position the windscreen wiper drive, install the screws and tighten them to a torque of 10 Nm.
33. Attach the windscreen wiper linkage to the drive, install the nut and tighten it to a torque of 25 N·m.
34. Assemble the steering column, install the steering shaft support, tighten the mounting nuts and tighten them to a torque of 25 N·m.
35. Install the Torx screw into the lower steering shaft clamp and tighten it to 25 Nm.
36. Install the center console support and tighten the screws to 10 Nm.
37. Install the parking brake lever bracket to the body, tighten the screws and tighten them to a torque of 25 N·m.
38. Reinstall the automatic transmission selector bracket and tighten the nuts to 25 Nm.
39. Install the automatic transmission selector assembly.
AUTOMATIC TRANSMISSION - GM 5L40-E, REPAIR WORK, Selector lever - gear selector assembly.
40. Install the passenger side instrument panel upper trim.
CAR INTERIOR PARTS, REPAIR WORK, Upper control panel trim - passenger side.
41. Install the driver's side instrument panel upper trim.
CAR INTERIOR PARTS, REPAIR WORK, Upper control panel trim - driver's side.
42. Install the upper A-pillar covers.
CAR INTERIOR PARTS, REPAIR WORK, Trim - pillar "A" - upper.
43. Install the "A" pillar trim.
CAR INTERIOR PARTS, REPAIR WORK, Trim - pillar "A" - lower.
44. Install the support for the driver's left foot.
CAR INTERIOR PARTS, REPAIR WORK, Footrest frame - left-hand steering wheel.
45. Connect the air ducts to the heater and secure them.
46. Install the center console side panel.
CAR INTERIOR PARTS, REPAIR WORK, Side panel - center console.
47. Install the parking brake lever assembly.
BRAKE SYSTEM, REPAIR WORK, Lever assembly - parking brake.
48. Reinstall the air suspension control panel.
CAR INTERIOR PARTS, REPAIR WORK, Switch panel - air suspension.
49. Install the heater control unit.
HEATING AND VENTILATION, REPAIR WORK, Controls - heater (electronic control unit) (ECU).
50. Install the front seats.
SEATS, REPAIR WORK, Front seat.
51. Install the air intake box in place.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
52. Fill the air conditioning system.
AIR CONDITIONING SYSTEM, AIR CONDITIONER DRAINING, REFRIGERANT RECOVERY AND CHARGING, Air conditioner draining - refrigerant recovery and refilling.
53. Fill the engine with coolant.
COOLING SYSTEM: Td6, ADJUSTMENTS AND MAINTENANCE, Draining the coolant, flushing the system and filling.
54. Connect the negative battery terminal.
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