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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 >> Removal Procedure

Removal 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.
  1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM (L61) in Engine Cooling.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  3. Remove the bolt connecting the evaporator lines to the evaporator.
  4. Remove the evaporator lines from the evaporator.
  5. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  6. Use the J 38185  in order to reposition the hose clamps.
  7. Disconnect the heater hoses from the heater core.
  8. Lower the vehicle.
  9. Remove the evaporator case drain tube.
  10. Remove the I/P carrier. Refer to INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT (CHEVROLET) or INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT (PONTIAC) in Instrument Panel, Gages and Console.
  11. Disconnect the wiring harness from the cross vehicle beam (1).
    Fig 1: Locating Wiring Harness At Cross Vehicle Beam
    G01579699Courtesy of GENERAL MOTORS CORP.
  12. Remove the attaching bolts from the right and left side of the HVAC module.
  13. Remove the bolts (2) from the cross vehicle beam.

    Important:  Place the steering column in the straight tilt position using the tilt lever.

  14. Remove the cross vehicle beam (1) from the front of the vehicle.
  15. Remove the floor air outlet.
  16. Disconnect the wiring harness from the HVAC module assembly.
  17. Disconnect the electrical connections at the following locations:
    • The blower motor
    • The blower resistor
  18. Remove the HVAC module attaching bolts near the heater hoses and the A/C evaporator lines.
    19. NOTE: Do not tilt the HVAC module assembly, or coolant may leak out.
    Fig 2: Locating HVAC Module Mounting Bracket Screw
    G01579700Courtesy of GENERAL MOTORS CORP.
  19. Remove the HVAC module assembly screw (2) from the mounting bracket (1).
  20. Remove the module from the vehicle.
    Fig 3: Removing/Installing HVAC Module
    G01579701Courtesy of GENERAL MOTORS CORP.
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