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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1594 (Heating, Ventilation, And Air Conditioning) >> Repair Instructions >> HVAC Module Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: HVAC Module, Bolts & Cross Car Beam
    GM933686Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure the HVAC module seals are flush and even as they meet their mating surfaces. This will reduce the chance of leaks and ensure proper fit.
  1. Inspect the front of dash seal for proper alignment.
  2. Inspect the seal mating surfaces to ensure there are no obstructions.
    3. IMPORTANT: Make sure the plastic molded in bracket at the center of the HVAC module is forward of the cross car beam during installation.
  3. Loose hang the HVAC module from the cross car beam.
    4. Fig 2: Metal Bracket & Nut
    GM933704Courtesy of GENERAL MOTORS CORP.
  4. Install the metal bracket to the left side of the HVAC module.
    5. NOTE: Refer to Fastener Notice .
  5. Install the metal bracket bolts to the left side of the HVAC module.

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

    6. Fig 3: HVAC Module Seal & Nuts
    GM931912Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: New front of dash seal nuts must be used to prevent leaks.
  6. Install the HVAC module seal nuts to the front of dash. Draw the HVAC module to the front of dash evenly by alternating between the seal nuts.

    Tighten:  Tighten the nuts to 8 N.m (71 lb in).

    7. Fig 4: HVAC Module, Bolts & Cross Car Beam
    GM933686Courtesy of GENERAL MOTORS CORP.
  7. Install the HVAC module bolts to the right side of the cross car beam.
  8. Push up on the right side of the HVAC module while tightening the HVAC module bolts to the cross car beam.

    Tighten:  Tighten the bolts to 8 N.m (71 lb in).

  9. Install the HVAC module bolt to the left side of the cross car beam.

    Tighten:  Tighten the bolt to 8 N.m (71 lb in).

  10. Install the HVAC module nuts to the left side and center of the cross car beam.

    Tighten:  Tighten the nuts to 8 N.m (71 lb in).

    11. Fig 5: Defroster Duct
    GM1644813Courtesy of GENERAL MOTORS CORP.
  11. Install the defroster duct to the HVAC module.
  12. Install the defroster duct nuts to the HVAC module.

    Tighten:  Tighten the nuts to 2.5 N.m (22 lb in).

  13. Install the defroster duct retainer to the cross car beam.
  14. Connect the I/P wire harness clips to the HVAC module.
    15. Fig 6: Blower Motor Electrical Connector & I/P Wire Harness
    GM932498Courtesy of GENERAL MOTORS CORP.
  15. Connect the blower motor electrical connector to the I/P wire harness.
  16. Connect the blower motor resistor electrical connector to the I/P wire harness.
  17. Connect the HVAC module electrical connector to the I/P wire harness.
    18. Fig 7: Center I/P Duct
    GM1644812Courtesy of GENERAL MOTORS CORP.
  18. Install the center I/P duct to the cross car beam.
  19. Install the center I/P duct retainers to the cross car beam.
    20. Fig 8: Center Floor Air Outlet Duct
    GM933579Courtesy of GENERAL MOTORS CORP.
  20. Install the center floor air outlet by sliding forward onto the front floor air outlet then down and rearward over the rear floor air outlet.
  21. Install the shift control bracket. Refer to Shift Control Replacement for the 5AT transmission or Automatic Transmission Control Replacement for the 4T45-E transaxle or Shift Control Replacement for the Getrag 5 speed transmission.
  22. Install the I/P retainer. Refer to Instrument Panel Retainer Replacement .
    23. Fig 9: Heater Inlet, Hose Clamp & Heater Core
    GM931806Courtesy of GENERAL MOTORS CORP.
  23. Install the heater inlet hose to the heater core.
  24. Install the heater inlet hose clamp to the heater core using SA9111E  . See Special Tools .
    25. Fig 10: Heater Outlet, Hose Clamp & Heater Core
    GM931798Courtesy of GENERAL MOTORS CORP.
  25. Install the heater outlet hose to heater core outlet.
  26. Install the heater outlet hose clamp to the heater core using SA9111E  . See Special Tools .
    27. Fig 11: Evaporator Outlet Hose, Liquid Line & TXV
    GM1506429Courtesy of GENERAL MOTORS CORP.
  27. Ensure the mating surfaces are clean and free of debris, and install new seal washers to the evaporator outlet hose and the liquid line. Refer to Sealing Washer Replacement .
  28. Install the evaporator outlet hose and the liquid line to the TXV.
    29. Fig 12: Evaporator Outlet Hose, Liquid Line Retainer Plate, Nut & TXV
    GM1506428Courtesy of GENERAL MOTORS CORP.
  29. Install the evaporator outlet hose and liquid line nut to the TXV.

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

  30. Fill the coolant. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (GE 47716 Fill) .
  31. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging .
  32. Test the affected A/C joints for leaks using J 39400-A  . See Special Tools .
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