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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 147 (Heating, Ventilation And Air Conditioning) >> Repair Instructions >> HVAC Module Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  1. Install the HVAC module assembly. See Figure. Align the mounting bracket (1) to the hole. See Figure. Install the screw (2) to the mounting bracket.

    Tighten 

    Tighten the bolt to 2 N.m (18 lb in).

  2. Install the HVAC module attaching bolts near the heater hoses and the A/C evaporator lines.

    Tighten 

    Tighten the bolts to 2 N.m (18 lb in).

  3. Connect the electrical connections at the following locations:
    • The blower motor
    • The blower resistors
  4. Connect the wiring harness to the HVAC module assembly.
  5. Install the floor air outlet.
  6. Install the cross vehicle beam (1) to the front of the dash. See Figure.
  7. Install the bolts (2) and the studs (3) to the cross vehicle beam (1).

    Tighten 

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

  8. Install the support bolts on the right and left side of the HVAC module.

    Tighten 

    Tighten the fittings to 2 N.m (18 lb in).

  9. Connect the wiring harness to the cross vehicle beam (1).
  10. Install the I/P carrier. Refer to Instrument Panel (I/P) Carrier Replacement (Chevrolet) on page 8-501  or Instrument Panel (I/P) Carrier Replacement (Pontiac) on page 8-503  in Instrument Panel, Gages and Console.
  11. Raise and support the vehicle.
  12. Install the evaporator case drain tube.
  13. Connect the heater hoses to the heater core.
  14. Use the J 38185  in order to reposition the hose clamps.
  15. Lower the vehicle.
  16. Connect the evaporator tube to the evaporator.

    Tighten 

    Tighten the fittings to 24 N.m (18 lb ft).

  17. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  18. Leak test the fittings of the component using J 39400-A. 
  19. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM (L61) in Engine Cooling.
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