Heater System: Removal & Installation Saturn SL II

REMOVAL & INSTALLATION

1. Disconnect negative battery cable. Depress center pins inward partway and release heater control panel cover push-pins, and remove cover. Disconnect traction control, fog light, rear defogger electrical connector (if equipped). Remove radio. Disconnect heater control panel electrical connectors and remove harness clip. Squeeze temperature and mode cables lock taps and remove cables. Remove heater control panel.
2. To install, reverse removal procedure. Tighten mounting screws to 22 INCH lbs. (2.5 N.m). Ensure temperature and mode cables are properly adjusted. See «ADJUSTMENTS»(ref-246-S10557450332000030800000) .

Removal

1. Disconnect negative battery cable. Drain cooling system. Disconnect heater hoses from heater core. Carefully blow remainder of coolant out of heater core with air hose to prevent spilling coolant inside of vehicle.
2. Remove left and right lower trim panel extensions from below A/C-heater control panel. Pull outward at lock position closest to firewall and rotate panel outward, disengaging hinges. Remove instrument panel closeout panel by pulling out at top edge and rotating top downward.
3. Remove lower heater duct using care not to damage seal between heater duct and rear floor heater duct. Remove temperature control cable. Remove heater core left side cover. Remove lower heater core cover. (Scheme 1) Remove heater core bracket and heater core.

Installation

To install heater core, reverse removal procedure. Fill cooling system. Ensure control cables are properly adjusted. See ADJUSTMENTS .

Scheme 1

Disconnect blower motor connector. Remove blower motor screws and lower blower motor straight down. To install, reverse removal procedure.

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Locate upper trim panel screws hidden under plastic screw covers at top center of instrument panel. Remove screws. Lift upper trim panel at clips located on rear edge (to disengage clips). Lift upper trim panel at each outer corner and pull rearward to remove. Remove upper trim panel insulator.
2. Remove screws and unsnap windshield defroster duct from A/C-heater module. Lift defrost duct and move it to the right, to gain access to blower motor resistor. Remove blower motor resistor connector and screws. Remove blower motor resistor. To install, reverse removal procedure.

1. Locate recirculation door motor on passenger side of A/C-heater module. Disconnect recirculation door motor electrical connector. Remove recirculation motor mounting screws. Pull motor straight off of recirculation door shaft.
2. To install, reverse removal procedure. Align flats on motor shaft and recirculation door shaft. Rotate motor back and forth to engage recirculation door shaft and motor.