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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1666 (Heating, Ventilation And Air Conditioning) >> Repair Instruction >> HVAC Module Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Buick Regal and 2003 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install new seals (1,2,3) to the outer HVAC module assembly.
    Fig 1: Locating Seals On Outer HVAC Module Assembly
    G01568651Courtesy of GENERAL MOTORS CORP.
  2. Install the HVAC module assembly to the vehicle.
    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).

    Fig 2: Removing HVAC Module Assembly Mounting Nuts
    G01568652Courtesy of GENERAL MOTORS CORP.
  4. Install the evaporator drain elbow.
    Fig 3: Installing Evaporator Drain Elbow
    G01568653Courtesy of GENERAL MOTORS CORP.
  5. Connect the electrical connectors to the HVAC module assembly.
  6. Connect the vacuum hoses to the HVAC module assembly.
  7. Install the heater core outlet cover.
  8. Install the screws to the heater core outlet cover.

    Tighten 

    Tighten the screws to 1.5 N.m (13 lb in).

    Fig 4: Positioning Heater Core Outlet Cover
    G01568654Courtesy of GENERAL MOTORS CORP.
  9. Install the cross vehicle beam to the vehicle.
    Fig 5: Installing Cross Vehicle Beam To Vehicle
    G01568655Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do NOT tighten the bolts at this time.
  10. Install the bolts which secure the right cross vehicle beam to the hinge pillar.
    Fig 6: Locating Bolts Which Secure Right Cross Vehicle Beam To Hinge Pillar
    G01568656Courtesy of GENERAL MOTORS CORP.
  11. Install the bolts which secure the left cross vehicle beam to the hinge pillar.

    Tighten 

    Tighten the bolts to 20 N.m (15 lb ft).

    Fig 7: View Of Bolts Which Secure Left Cross Vehicle Beam To Hinge Pillar
    G01568657Courtesy of GENERAL MOTORS CORP.
  12. Install the bolt (1) to the cross vehicle beam.

    Tighten 

    Tighten the bolt to 20 N.m (15 lb ft).

    Fig 8: Installing Bolt To Cross Vehicle Beam
    G01568658Courtesy of GENERAL MOTORS CORP.
  13. Install the bolts to the upper support brackets of the HVAC module.

    Tighten 

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

    Fig 9: Installing Bolts To Upper Support Brackets Of HVAC Module
    G01568659Courtesy of GENERAL MOTORS CORP.
  14. Install the center support bracket to the HVAC module.
  15. Install the bolts to the center support bracket of the HVAC module.

    Tighten 

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

  16. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.
  17. Install the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam.
    Fig 10: Installing Center Support Bracket To HVAC Module
    G01568660Courtesy of GENERAL MOTORS CORP.
  18. Install the BCM bracket and the bolts.

    Tighten 

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

    Fig 11: Installing BCM Bracket & Bolts
    G01568661Courtesy of GENERAL MOTORS CORP.
  19. Install the relay bracket and the bolts.

    Tighten 

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

    Fig 12: Installing Relay Bracket & Bolts
    G01568662Courtesy of GENERAL MOTORS CORP.
  20. Install the right and left side air distribution ducts.
  21. Install the screws to the right and left side air distribution duct.

    Tighten 

    Tighten the screws to 1.5 N.m (13 lb in).

    Fig 13: Installing Right & Left Side Air Distribution Ducts
    G01568663Courtesy of GENERAL MOTORS CORP.
  22. Install the steering column support bracket to the cross vehicle beam.
  23. Install the steering column support bracket nuts and bolts.

    Tighten 

    Tighten the nuts and bolts to 50 N.m (37 lb ft).

  24. Install the brake pedal. Refer to BRAKE PEDAL ASSEMBLY in Disc & Drum.
  25. Connect all disconnected ground wires.
  26. Install the passenger side SIR inflator module. Refer to AIR BAG MODULES
  27. Install the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT -- INSTRUMENT PANEL (I/P) in Instrument Panel, Gages and Console.
    Fig 14: Installing Steering Column Support Bracket Nuts & Bolts
    G01568664Courtesy of GENERAL MOTORS CORP.
  28. Connect the inlet and outlet heater hose to the heater core.
    IMPORTANT: Reposition the heater core hose clamps in the indicated location.
  29. Use J 38185  in order to reposition the heater hose inlet and outlet clamp to the heater core.
    Fig 15: Aligning Inlet & Outlet Heater Hose Clamps To Heater Core
    G01568665Courtesy of GENERAL MOTORS CORP.
  30. Connect the evaporator tube to the evaporator.
  31. Connect the accumulator tube to the evaporator.
  32. Install the accumulator tube to evaporator core block fitting bolt.

    Tighten 

    Tighten the bolt to 16 N.m (12 lb ft).

    Fig 16: Connecting Accumulator Tube To Evaporator
    G01568666Courtesy of GENERAL MOTORS CORP.
  33. Install the fuel injector sight shield (3.8L only). Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mecanical-3.8L.
  34. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  35. Evacuate and recharge the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING  .
  36. Leak test the fittings of the component using J 39400-A. 
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