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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 242 (Heating, Ventilation And Air Conditioning - Gas) >> Repair Instructions >> HVAC Module Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  1. Install the HVAC module assembly. Align the mounting bracket (1) to the front of dash slot and mounting bolt hole.
  2. Install the bolt (2) to the mounting bracket.

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

    Fig 1: Identifying HVAC Module Assembly Mounting Bracket
    GM672767Courtesy of GENERAL MOTORS CORP.
  3. 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).

  4. Connect the electrical connections at the following locations:
    • The blower motor (3)
    • The blower resistors (3)
      • Fig 2: Identifying HVAC Module Electrical Connections
      GM1337026Courtesy of GENERAL MOTORS CORP.
  5. Connect the wiring harness to the HVAC module assembly (2).
  6. Install the floor air outlet.
  7. Install the cross vehicle beam (1) to the front of the dash.
  8. 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).

    Fig 3: Exploded View Of Cross Vehicle Beam
    GM288341Courtesy of GENERAL MOTORS CORP.
  9. Install the support bolts on the right and left side of the HVAC module.

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

  10. Connect the wiring harness to the cross vehicle beam (1).
  11. Install 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.
  12. Raise and support the vehicle.
  13. Install the evaporator case drain tube.
  14. Connect the heater hoses to the heater core.
  15. Use the J 38185  in order to reposition the hose clamps.
  16. Lower the vehicle.
  17. Connect the evaporator tube to the evaporator.

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

  18. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  19. Leak test the fittings of the component using J 39400-A  .
  20. Fill the cooling system. Refer to Draining and Filling Cooling System (L61) in Engine Cooling.
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