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HOMESERVICE MANUALSSATURN2002SL1 L4-1.9L SOHC VIN 8REPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCONTROL ASSEMBLYSERVICE AND REPAIRHVAC CONTROLLER AND CABLES
2002 Saturn SL1 L4-1.9L SOHC VIN 8
HVAC Controller and Cables
2002 Saturn SL1 L4-1.9L SOHC VIN 8SECTION HVAC Controller and Cables
REMOVAL
1. Loosen upper trim panel:
1.1 Remove screws located under upper trim panel on passenger on passenger's side of vehicle.
NOTE: Be careful not to damage VIN plate when removing or replacing upper trim panel.
1.2 Disengage clips at locations by grasping edges of upper trim panel and lifting up.
2. Loosing steering column filler panel screws.
NOTE: Do not remove weatherstrips. Adhesion will be lost if removed.
3. Remove left endcap assembly:
3.1 Remove screws.
3.2 Carefully disengage clips at I/P retainer assembly locations. Use of a blunt tool will aid in disengaging clips.
3.3 Maneuver the assemblies past inner I/P retainer assembly and weatherstrips.
4. Gently pry edges of ignition lock bezel with a blunt tool and separate from lower shroud.
5. Remove screws from lower steering column shroud.
6. Lower steering column by pushing down on steering column adjusting handle.
7. Lift and remove upper shroud from steering column.
8. Remove I/P bezel:
8.1 Disengage clips from retainer assembly by grasping edges of bezel near clip location and pull outward.
8.2 Depress wiring harness connector tabs and remove harness from dimmer/traction control switch assembly.
9. Remove radio:
9.1 Remove radio screws.
9.2 Pull radio out slightly to access rear of radio.
9.3 Disconnect electrical connector, antenna, and ground strap connector.
10. Remove HVAC controller:
10.1 Remove screws.
10.2 Disconnect HVAC blower switch connector.
10.3 Disconnect HVAC control head connector.
10.4 Remove temperature cable by squeezing lock tabs together white pulling cable (coiled end) straight up beyond retaining tabs.
10.5 Remove mode cable by squeezing lock tabs together while pulling cable (coiled end) straight up beyond retaining tabs.
INSTALLATION
IMPORTANT: Make sure wiring harnesses do not interfere with control lever movement.
Cable identification:
^ Temperature Cable - White
^ Mode Cable - Black
1. Install HVAC controller:
1.1 Install mode valve cable onto mode valve pin.
1.2 Snap slot on cable into HVAC controller base.
1.3 Repeat steps for temperature cable.
1.4 Install blower switch connector.
1.5 Install HVAC controller connector.
1.6 Install screws
Torque:
HVAC Controller-to-I/P Retainer: 2.5 N.m (22 in-lbs)
2. Install radio:
2.1 Connect wiring harness(es).
2.2 Connect ground strap.
2.3 Connect antenna lead.
2.4 Install screws.
Torque:
Radio-to-I/P Retainer: 2.5 N.m (22 in-lbs)
3. Install I/P cluster bezel:
3.1 Connect dimmer/traction control switch wiring harnesses.
3.2 Position I/P cluster bezel by lining up clip location.
3.3 Snap I/P cluster bezel in place by pushing at clip locations.
4. Position upper steering column shroud.
5. Position lower steering column shroud and install screws.
Torque:
Steering Column Shroud Fasteners: 1.5 N.m (13 in-lbs)
6. Install ignition bezel.
6.1 Align peg of ignition bezel with the cut-out in lower shroud.
6.2 Snap into place.
IMPORTANT: Ensure that endcap bottom portion is inside of the filler panel assembly.
7. Install left endcap assembly:
7.1 Maneuver the assembly past inner I/P retainer assembly and weatherstrips.
7.2 Snap clips into I/P retainer assembly locations.
7.3 Install screws.
Torque:
I/P Endcap Retaining Screws: 2.5 N.m (22 in-lbs)
8. Install steering column filler panel screws.
Torque:
Steering Column Filler Panel Fasteners: 2.5 N.m (22 in-lbs)
NOTE: Be careful not to damage VIN plate when removing or replacing upper trim panel.
IMPORTANT: Be sure upper trim panel seal is correctly seated on forward edge before installing upper trim panel.
9. Install I/P upper trim panel:
9.1 Ensure that hook-and-loop fasteners on upper trim panel are correctly inserted.
9.2 Position upper trim panel on retainer assembly.
9.3 Align tabs on sides of upper trim panel with openings in windshield garnish molding.
9.4 Align clips and clip location.
9.5 Firmly snap in clips at clip locations.
9.6 Install screws on underside of upper trim panel on passenger 5 side of vehicle.
Torque:
I/P Upper Trim Panel Fastener: 6 N.m (53 in-lbs)
1. Loosen upper trim panel:
1.1 Remove screws located under upper trim panel on passenger on passenger's side of vehicle.
NOTE: Be careful not to damage VIN plate when removing or replacing upper trim panel.
1.2 Disengage clips at locations by grasping edges of upper trim panel and lifting up.
2. Loosing steering column filler panel screws.
NOTE: Do not remove weatherstrips. Adhesion will be lost if removed.
3. Remove left endcap assembly:
3.1 Remove screws.
3.2 Carefully disengage clips at I/P retainer assembly locations. Use of a blunt tool will aid in disengaging clips.
3.3 Maneuver the assemblies past inner I/P retainer assembly and weatherstrips.
4. Gently pry edges of ignition lock bezel with a blunt tool and separate from lower shroud.
5. Remove screws from lower steering column shroud.
6. Lower steering column by pushing down on steering column adjusting handle.
7. Lift and remove upper shroud from steering column.
8. Remove I/P bezel:
8.1 Disengage clips from retainer assembly by grasping edges of bezel near clip location and pull outward.
8.2 Depress wiring harness connector tabs and remove harness from dimmer/traction control switch assembly.
9. Remove radio:
9.1 Remove radio screws.
9.2 Pull radio out slightly to access rear of radio.
9.3 Disconnect electrical connector, antenna, and ground strap connector.
10. Remove HVAC controller:
10.1 Remove screws.
10.2 Disconnect HVAC blower switch connector.
10.3 Disconnect HVAC control head connector.
10.4 Remove temperature cable by squeezing lock tabs together white pulling cable (coiled end) straight up beyond retaining tabs.
10.5 Remove mode cable by squeezing lock tabs together while pulling cable (coiled end) straight up beyond retaining tabs.
INSTALLATION
IMPORTANT: Make sure wiring harnesses do not interfere with control lever movement.
Cable identification:
^ Temperature Cable - White
^ Mode Cable - Black
1. Install HVAC controller:
1.1 Install mode valve cable onto mode valve pin.
1.2 Snap slot on cable into HVAC controller base.
1.3 Repeat steps for temperature cable.
1.4 Install blower switch connector.
1.5 Install HVAC controller connector.
1.6 Install screws
Torque:
HVAC Controller-to-I/P Retainer: 2.5 N.m (22 in-lbs)
2. Install radio:
2.1 Connect wiring harness(es).
2.2 Connect ground strap.
2.3 Connect antenna lead.
2.4 Install screws.
Torque:
Radio-to-I/P Retainer: 2.5 N.m (22 in-lbs)
3. Install I/P cluster bezel:
3.1 Connect dimmer/traction control switch wiring harnesses.
3.2 Position I/P cluster bezel by lining up clip location.
3.3 Snap I/P cluster bezel in place by pushing at clip locations.
4. Position upper steering column shroud.
5. Position lower steering column shroud and install screws.
Torque:
Steering Column Shroud Fasteners: 1.5 N.m (13 in-lbs)
6. Install ignition bezel.
6.1 Align peg of ignition bezel with the cut-out in lower shroud.
6.2 Snap into place.
IMPORTANT: Ensure that endcap bottom portion is inside of the filler panel assembly.
7. Install left endcap assembly:
7.1 Maneuver the assembly past inner I/P retainer assembly and weatherstrips.
7.2 Snap clips into I/P retainer assembly locations.
7.3 Install screws.
Torque:
I/P Endcap Retaining Screws: 2.5 N.m (22 in-lbs)
8. Install steering column filler panel screws.
Torque:
Steering Column Filler Panel Fasteners: 2.5 N.m (22 in-lbs)
NOTE: Be careful not to damage VIN plate when removing or replacing upper trim panel.
IMPORTANT: Be sure upper trim panel seal is correctly seated on forward edge before installing upper trim panel.
9. Install I/P upper trim panel:
9.1 Ensure that hook-and-loop fasteners on upper trim panel are correctly inserted.
9.2 Position upper trim panel on retainer assembly.
9.3 Align tabs on sides of upper trim panel with openings in windshield garnish molding.
9.4 Align clips and clip location.
9.5 Firmly snap in clips at clip locations.
9.6 Install screws on underside of upper trim panel on passenger 5 side of vehicle.
Torque:
I/P Upper Trim Panel Fastener: 6 N.m (53 in-lbs)
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.