Dash Panel Outer Insulator Replacement (without LM2)

Single Use Fasteners and Components Air Conditioning Evaporator Thermal Expansion Valve Seal - Large Air Conditioning Evaporator Thermal Expansion Valve Seal - Small

Warning

In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Warning

Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury. Removal Procedure

1. Recover the refrigerant. Refrigerant Recovery and Recharging
2. Drain the coolant. Cooling System Draining and Filling

Dash Panel Outer Insulator Replacement (without LM2) — figure 1

3. Plenum Front Panel Outer Reinforcement (1) » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation

Dash Panel Outer Insulator Replacement (without LM2) — figure 2

4. Heater Outlet Hose Retainer (2) » Disengage
5. Heater Outlet Hose (1) » Remove
6. Heater Outlet Hose Retainer (4) » Disengage
7. Heater Inlet Hose (3) » Remove

Dash Panel Outer Insulator Replacement (without LM2) — figure 3

8. Retainer (1) » Disengage [2x]
9. Auxiliary Heater Inlet and Outlet Hose (2) @ Heater Core » Remove [2x]

Dash Panel Outer Insulator Replacement (without LM2) — figure 4

10. Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) » Remove
11. Air Conditioning Refrigerant Heat Exchanger (2) » Remove
12. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) » Remove and DISCARD
13. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) » Remove and DISCARD
14. Raise and support the vehicle. Lifting and Jacking the Vehicle
15. Remove the left front tire and wheel assembly. Tire and Wheel Removal and Installation

Dash Panel Outer Insulator Replacement (without LM2) — figure 5

16. { If equipped } Front Tire Front Air Deflector Bolt (1) » Remove

Dash Panel Outer Insulator Replacement (without LM2) — figure 6

17. Front Wheelhouse Liner Bolt (1) » Remove [3x]

Dash Panel Outer Insulator Replacement (without LM2) — figure 7

Note

Quantity of fasteners may vary based on option content.

18. Front Wheelhouse Liner Bolt (1) » Remove [3x]
19. Front Wheelhouse Liner Retainer (2) » Remove

Dash Panel Outer Insulator Replacement (without LM2) — figure 8

20. Front Wheelhouse Liner Bolt (1) » Remove [3x]

Dash Panel Outer Insulator Replacement (without LM2) — figure 9

21. Front Wheelhouse Liner Bolt (1) » Remove [3x]

Dash Panel Outer Insulator Replacement (without LM2) — figure 10

22. Front Wheelhouse Liner - Left Side (1) » Remove

Dash Panel Outer Insulator Replacement (without LM2) — figure 11

23. Exhaust Heat Shield Retainer (1) » Remove [2x]

Dash Panel Outer Insulator Replacement (without LM2) — figure 12

24. Exhaust Heat Shield Retainer (1) » Remove

Dash Panel Outer Insulator Replacement (without LM2) — figure 13

25. Exhaust Heat Shield Retainer (1) » Remove

Dash Panel Outer Insulator Replacement (without LM2) — figure 14

Note

Remove the exhaust heat shield through the wheel opening.

26. Exhaust Heat Shield (1) » Remove
27. Lower the vehicle.

Dash Panel Outer Insulator Replacement (without LM2) — figure 15

28. Dash Panel Outer Insulator Retainer - Right Side (1) » Remove [3x]

Dash Panel Outer Insulator Replacement (without LM2) — figure 16

29. Dash Panel Outer Insulator Retainer - Left Side (1) » Remove

Dash Panel Outer Insulator Replacement (without LM2) — figure 17

30. Pull the dash panel outer insulator (1) slightly forward and upward to remove. Installation Procedure

31. Dash Panel Outer Insulator (1) » Install

32. Dash Panel Outer Insulator Retainer - Left Side (1) » Install

33. Dash Panel Outer Insulator Retainer - Right Side (1) » Install [3x]

34. Raise the vehicle.

35. Exhaust Heat Shield (1) » Install

36. Exhaust Heat Shield Retainer (1) » Install

37. Exhaust Heat Shield Retainer (1) » Install

38. Exhaust Heat Shield Retainer (1) » Install and tighten [2x] — Fastener Specifications

39. Front Wheelhouse Liner - Left Side (1) » Install

Caution

Refer to Fastener Caution.

10. Front Wheelhouse Liner Bolt (1) » Install and tighten [3x] — Fastener Specifications

11. Front Wheelhouse Liner Bolt (1) » Install and tighten [3x] — Fastener Specifications

Note

Quantity of fasteners may vary based on option content.

12. Front Wheelhouse Liner Retainer (2) » Install

13. Front Wheelhouse Liner Bolt (1) » Install and tighten [3x] — Fastener Specifications

14. Front Wheelhouse Liner Bolt (1) » Install and tighten [3x] — Fastener Specifications

15. { If equipped } Front Tire Front Air Deflector Bolt (1) » Install and tighten — Fastener Specifications

16. Lower the vehicle.

17. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) » Install NEW

18. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) » Install NEW

19. Air Conditioning Refrigerant Heat Exchanger (2) » Install

20. Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) » Install and tighten — Fastener Specifications

21. Auxiliary Heater Inlet and Outlet Hose (2) @ Heater Core » Install [2x]

22. Retainer (1) » Engage [2x]

23. Heater Inlet Hose (3) » Install

24. Heater Outlet Hose Retainer (4) » Engage

25. Heater Outlet Hose (1) » Install

26. Heater Outlet Hose Retainer (2) » Engage

Dash Panel Outer Insulator Replacement (without LM2) — figure 18

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

27. Inspect the plenum and the frame surfaces of where the plenum is removed.

28. Clean areas that the bead is broken or damaged with a plastic scrapper on the body and plenum.

29. Apply General Motors recommended Strip-Calk or equivalent to the plenum areas that are needed. Adhesives, Fluids, Lubricants, and Sealers

30. Plenum Front Panel Outer Reinforcement (1) » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

31. Fill the cooling system. Cooling System Draining and Filling

32. Recharge the refrigerant. Refrigerant Recovery and Recharging

33. Inspect for refrigerant leaks.

34. Inspect for coolant leaks.