Dash Panel Outer Insulator Replacement (with LM2)

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

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

Dash Panel Outer Insulator Replacement (with LM2) — figure 1

3. Air Cleaner Outlet Duct Clamp (1) » Loosen [2x]
4. Air Cleaner Outlet Front Duct (2) » Remove

Dash Panel Outer Insulator Replacement (with LM2) — figure 2

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

Dash Panel Outer Insulator Replacement (with LM2) — figure 3

6. Air Cleaner Outlet Duct Clamp (1) » Loosen
7. Air Cleaner Outlet Duct (2) » Remove

Dash Panel Outer Insulator Replacement (with LM2) — figure 4

8. Heater Outlet Hose Retainer (2) » Disengage
9. Heater Outlet Hose (1) » Remove
10. Heater Outlet Hose Retainer (4) » Disengage
11. Heater Inlet Hose (3) » Remove

Dash Panel Outer Insulator Replacement (with LM2) — figure 5

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

Dash Panel Outer Insulator Replacement (with LM2) — figure 6

14. Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) » Remove
15. Air Conditioning Refrigerant Heat Exchanger (2) » Remove
16. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) » Remove and DISCARD
17. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) » Remove and DISCARD
18. Raise and support the vehicle. Lifting and Jacking the Vehicle

Dash Panel Outer Insulator Replacement (with LM2) — figure 7

Note

Left side shown, right side similar.

19. Front Wheelhouse Liner Bolt - Right Side (1) » Remove [3x]

Dash Panel Outer Insulator Replacement (with LM2) — figure 8

Note

Left side shown, right side similar.

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

Dash Panel Outer Insulator Replacement (with LM2) — figure 9

21. Front Wheelhouse Front Liner - Right Side (1) » Reposition
22. Dash Panel Outer Insulator Retainer (2) » Remove
23. Lower the vehicle.

Dash Panel Outer Insulator Replacement (with LM2) — figure 10

24. Dash Panel Outer Insulator Retainer - Right Side (1) » Remove [2x]

Dash Panel Outer Insulator Replacement (with LM2) — figure 11

25. Dash Panel Outer Insulator Retainer - Left Side (1) » Remove [2x]

Dash Panel Outer Insulator Replacement (with LM2) — figure 12

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

27. Dash Panel Outer Insulator (1) » Install

28. Dash Panel Outer Insulator Retainer - Left Side (1) » Install [2x]

29. Dash Panel Outer Insulator Retainer - Right Side (1) » Install [2x]

30. Raise the vehicle.

31. Dash Panel Outer Insulator Retainer (2) » Install

32. Front Wheelhouse Front Liner - Right Side (1) » Install

Note

Left side shown, right side similar.

Caution

Refer to Fastener Caution.

7. Front Wheelhouse Liner Bolt - Right Side (1) » Install and tighten [3x] — Fastener Specifications

Note

Left side shown, right side similar.

8. Front Wheelhouse Liner Bolt - Right Side (1) » Install and tighten [3x] — Fastener Specifications

9. Lower the vehicle.

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

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

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

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

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

15. Retainer (1) » Engage [2x]

16. Heater Inlet Hose (3) » Install

17. Heater Outlet Hose Retainer (4) » Engage

18. Heater Outlet Hose (1) » Install

19. Heater Outlet Hose Retainer (2) » Engage

20. Air Cleaner Outlet Duct (2) » Install

21. Air Cleaner Outlet Duct Clamp (1) » Tighten — Fastener Specifications

Dash Panel Outer Insulator Replacement (with LM2) — figure 13

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.

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

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

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

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

26. Air Cleaner Outlet Front Duct (2) » Install

27. Air Cleaner Outlet Duct Clamp (1) » Tighten [2x] — Fastener Specifications

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

29. Recharge the refrigerant. Refrigerant Recovery and Recharging

30. Inspect for refrigerant leaks.

31. Inspect for coolant leaks.