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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 >> Removal Procedure

Removal 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. Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING  .
  2. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  3. Remove 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 Mechanical-3.8L.
  4. Remove the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT -- INSTRUMENT PANEL (I/P) in Instrument Panel, Gages and Console.
  5. Remove the passenger side SIR inflator module. Refer to AIR BAG MODULES
  6. Remove the brake pedal. Refer to BRAKE PEDAL ASSEMBLY in Disc & Drum.
  7. Disconnect any ground wires, as necessary.
  8. Remove the nuts and bolts from the steering column support bracket.
  9. Remove the steering column support bracket from the cross vehicle beam.
    Fig 1: Removing/Installing Right & Left Side Air Distribution Ducts
    G01568637Courtesy of GENERAL MOTORS CORP.
  10. Remove the screws from the right and left side air distribution duct.
  11. Remove the right and left side air distribution duct.
  12. Remove the bolts from the relay bracket and position the relay bracket aside.
    Fig 2: Removing Bolts From Relay Bracket
    G01568638Courtesy of GENERAL MOTORS CORP.
  13. Remove the bolts from the BCM bracket and position the BCM bracket aside.
  14. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
  15. Remove the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam.
    Fig 3: Removing Bolts From BCM Bracket
    G01568639Courtesy of GENERAL MOTORS CORP.
  16. Remove the bolts from the center support bracket of the HVAC module.
    Fig 4: Removing/Installing Center Support Bracket Mounting Bolts Of HVAC Module
    G01568640Courtesy of GENERAL MOTORS CORP.
  17. Remove the center support bracket of the HVAC module.
  18. Remove the bolts from the upper support brackets of the HVAC module.
    Fig 5: Removing Bolts From Upper Support Brackets Of HVAC Module
    G01568641Courtesy of GENERAL MOTORS CORP.
  19. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.
    Fig 6: View Of Bolts Which Secure Left Cross Vehicle Beam To Hinge Pillar
    G01568642Courtesy of GENERAL MOTORS CORP.
  20. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.
    Fig 7: Locating Bolts Which Secure Right Cross Vehicle Beam To Hinge Pillar
    G01568643Courtesy of GENERAL MOTORS CORP.
  21. Remove the bolt (1) from the cross vehicle beam.
    Fig 8: Removing Cross Vehicle Beam Mounting Bolt
    G01568644Courtesy of GENERAL MOTORS CORP.
  22. Remove the cross vehicle beam from the vehicle.
  23. Remove the accumulator tube to evaporator core block fitting bolt.
    Fig 9: Removing/Installing Evaporator Core Block Fitting Bolt
    G01568645Courtesy of GENERAL MOTORS CORP.
  24. Disconnect the accumulator tube from the evaporator.
  25. Disconnect the evaporator tube from the evaporator.
  26. Remove the O-ring seals and discard.
  27. Use J 38185  in order to position aside the heater hose inlet and outlet clamp at the heater core.
  28. Disconnect the inlet and outlet heater hose from the heater core.
    Fig 10: Aligning Inlet & Outlet Heater Hose Clamps From Heater Core
    G01568646Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Position the heater core outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly.
  29. Remove the screws from the heater core outlet cover.
  30. Remove the heater core outlet cover.
    Fig 11: Positioning Heater Core Outlet Cover
    G01568647Courtesy of GENERAL MOTORS CORP.
  31. Remove the evaporator drain elbow.
    Fig 12: Removing Evaporator Drain Elbow
    G01568648Courtesy of GENERAL MOTORS CORP.
  32. Remove the mounting nuts for the HVAC module assembly from the cowl.
    Fig 13: Removing HVAC Module Assembly Mounting Nuts
    G01568649Courtesy of GENERAL MOTORS CORP.
  33. Disconnect the vacuum hoses from the HVAC module assembly.
  34. Disconnect the electrical connectors from the HVAC module assembly.
  35. Remove the HVAC module assembly.
  36. Remove all of the seals (1,2,3) from the outer HVAC module assembly.
    Fig 14: Locating Seals On Outer HVAC Module Assembly
    G01568650Courtesy of GENERAL MOTORS CORP.
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