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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 >> Removal Procedure

Removal 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.
  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 in General Information.
  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: Exploded View Of Cross Vehicle Beam
    GM288341Courtesy 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.
    Fig 2: Identifying HVAC Module Assembly Mounting Bracket
    GM672767Courtesy of GENERAL MOTORS CORP.
  19. Remove the HVAC module assembly screw (2) from the mounting bracket (1).
    IMPORTANT: Do not tilt the HVAC module assembly, or coolant may leak out.
  20. Remove the HVAC module from the vehicle.
    Fig 3: View Of HVAC Module
    GM672770Courtesy of GENERAL MOTORS CORP.
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