American Car Craft HHR Firewall Brushed w_Cap 2006-2012 - Manual (Page 2)

1. Remove the two fender gaskets on either side of the engine bay and set them aside.
Remove the brake fluid cap. Remove the air filter box. This can be done by unplugging
the mass air flow harness just to the right of the main air tube. Loosen the main air tube
clamp and the large vacuum tube clamp to the left of the main air tube. Unplug the
main air intake tube from the inner fender wall. The air box itself attaches via 3 rubber
push in retainers. Simply pull up on the filter box to remove and set it aside.
2. You will notice that there is a wire harness snapped into the plastic wiper cowl
running along its entire length. Completely unsnap this harness and reattach it to the
wire harness running along the back of the engine using the zip ties provided. Allow the
harness to run below the brake fluid reservoir tank.
3. Detach the fuel line retainer from its vertical bracket. This will allow the line to drop
lower and out of the way. The fuel line has a secondary bracket in back of the engine
which will keep it safely in place. There will be a hard plastic vacuum line just to the
right of the fuel line. Simply rotate this line to a lower position.
4. Dettach the windshield washer fluid supply tube and re route it down along the other
tubes and harnesses and re attach. These steps have created a nice unobstructed plane
for the new firewall to fit over. Although it should not be necessary you may have to
adjust the aluminum a/c lines just to the right of the brake fluid reservoir. The lines are
made of a soft aluminum and will allow you to force an adjustment in its position if
necessary.
5. Now that you have prepared the car to receive the new firewall simply place it into
the area. At this time you will make any final adjustments to the a/c lines and or any
other hoses or wires that may be left in the way. Because the wiper cowl has a curve
from left to right you will need to push the firewall into the corners to achieve a correct
seating. You will also notice that the plastic wiper cowl is very flexible and can be
adjusted up or down to line up nicely with the edge of the new firewall. NOTE: Because
of this flexibility if you are planning to install our wiper cowl cover you will want to do
this first so as to line up the new firewall to the cover for the best looking end result.
6. You will notice that the firewall contains four mounting holes. Holding the firewall in a
nice flush position, pilot a 1/8 hole directly into the plastic wiper cowl. Be careful not to
pilot the hole to high. You must take your time and aim these first two center holes just
right. Once this is done secure the firewall by installing the oval head screws provided.
Be careful not to tighten the screws too tight as this will strip the soft plastic.
7. With the center of the firewall set, push the two ends of the firewall into the corners
until it is nice and flat against the wiper cowl then pilot and set the two remaining
screws.