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Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Seals From Outer HVAC Module Assembly
    GM1263072Courtesy of GENERAL MOTORS CORP.
  1. Install new seals (1,2,3) to the outer HVAC module assembly.
  2. Install the HVAC module assembly to the vehicle.
    3. Fig 2: Nuts That Secure HVAC Module Assembly To Dash
    GM507700Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the nuts which secure the HVAC module assembly to the dash.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    4. Fig 3: Evaporator Drain Elbow
    GM1284759Courtesy of GENERAL MOTORS CORP.
  4. Install the evaporator drain elbow.
  5. Connect the electrical connectors to the HVAC module assembly.
  6. Install the I/P carrier to the vehicle. Align the I/P carrier to the HVAC module assembly and the hinge pillars.
  7. Install the bolts to the right and the left I/P carrier.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    8. Fig 4: HVAC Module Assembly Upper Support Bolts
    GM1197447Courtesy of GENERAL MOTORS CORP.
  8. Install the bolts to the HVAC module assembly upper support bracket.

    Tighten:  Tighten the bolts to 4 N.m (36 lb in).

    9. Fig 5: Bracket Bolts From HVAC Module Assembly
    GM1273425Courtesy of GENERAL MOTORS CORP.
  9. Install the bolts to the HVAC module assembly lower support bracket (1).

    Tighten:  Tighten the bolts to 4 N.m (36 lb in).

  10. Install the bolt to the HVAC module assembly right support bracket (2).

    Tighten:  Tighten the bolt to 4 N.m (36 lb in).

  11. Position the I/P wiring harness to the original position.
  12. Connect any disconnected ground wires.
  13. Install the BCM.
  14. Install the brake pedal brace bolts to the I/P carrier.
  15. Position the brake pedal to the brake pedal brace.
  16. Install the brake pedal bolt and nut. Refer to Brake Pedal Assembly Replacement In Hydraulic Brakes.
  17. Seat the bottom junction block tabs and snap the top of the junction block to the passenger knee bolster.
  18. Install the junction block bolt.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

  19. Install the I/P trim pad. Refer to Trim Pad Replacement - Instrument Panel (I/P) .
    20. Fig 6: View Of Heater Hose To Heater Core
    GM1204093Courtesy of GENERAL MOTORS CORP.
  20. Connect the inlet heater hose to the heater core.
  21. Connect the outlet heater hose to the heater core.
  22. Use J 38185  in order to reposition the inlet heater hose clamp to the heater core.
  23. Use J 38185  in order to reposition the outlet heater hose clamp to the heater core.
  24. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L26) or Fuel Injector Sight Shield Replacement (L32) in Engine Mechanical.
  25. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  26. Install new sealing washers on the evaporator tube. Refer to Sealing Washer Replacement .
    27. Fig 7: Nut That Secures Evaporator Tube To TXV
    GM532742Courtesy of GENERAL MOTORS CORP.
  27. Connect the evaporator tube to the TXV.
  28. Install the evaporator tube to the TXV block fitting nut.

    Tighten:  Tighten the nut to 27 N.m (20 lb ft).

  29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls 3.8L.
  30. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  31. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  32. Leak test the fittings of the component using J 39400-A .
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