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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 819 (Heating, Ventilation And Air Conditioning) >> Repair Instructions >> HVAC Module Replacement - Auxiliary (Suburban/Yukon XL) >> Installation Procedure

Installation Procedure

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2003 GMC Yukon XL, 2003 GMC Yukon, 2003 Chevrolet Tahoe, 2003 Chevrolet Suburban, and 2003 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the auxiliary HVAC module assembly (3) to the vehicle.
  2. Install the two bolts (2,4) inside the vehicle in order to retain the auxiliary HVAC module to the vehicle.
    Fig 1: Installing Auxiliary HVAC Module To Vehicle
    G01454475Courtesy of GENERAL MOTORS CORP.
  3. Install the air distributor duct (3).
  4. Install the fastener (4)
    Fig 2: Installing Fastener For Air Distributor Duct
    G01454476Courtesy of GENERAL MOTORS CORP.
  5. Install the lower auxiliary air outlet (5).
  6. Install the fastener (4)
    Fig 3: Installing Fastener For Lower Auxiliary Air Outlet
    G01454477Courtesy of GENERAL MOTORS CORP.
  7. Install the upper auxiliary air duct (6) to the air distributor duct (3).
  8. Install the fastener (5)
  9. Connect the electrical connectors to the auxiliary HVAC module.
  10. Install the electronic suspension control module. Refer to ELECTRONIC SUSPENSION CONTROL MODULE REPLACEMENT (TAHOE/YUKON/ESCALADE) or ELECTRONIC SUSPENSION CONTROL MODULE REPLACEMENT (ESCALADE EXT) in Electronic Suspension Control.
  11. Install the right rear quarter trim panel. Refer to TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY) or TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN) in Interior Trim.
  12. Raise the vehicle.
    Fig 4: Installing Fastener For Upper Auxiliary Air Duct
    G01454478Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  13. Install the nuts (2) that secure the auxiliary HVAC module to the vehicle.

    Tighten: 

    Tighten the nuts to 9 N.m (80 lb in).

    Fig 5: Installing Nuts From Studs That Secure Auxiliary HVAC Module
    G01454479Courtesy of GENERAL MOTORS CORP.
  14. Install the air conditioning lines (2,3) and the nut (4) to the auxiliary HVAC module.

    Tighten: 

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

    Fig 6: Connecting Air Conditioning Lines To Auxiliary HVAC Module
    G01454480Courtesy of GENERAL MOTORS CORP.
  15. Install the heater lines (2,3) to the auxiliary HVAC module at the underside of vehicle.
  16. Remove the safety stands.
  17. Lower the vehicle.
  18. Fill the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  19. Recharge the refrigerant to the system. Refer to REFRIGERANT RECOVERY AND RECHARGING  .
    Fig 7: Installing Heater Lines To Auxiliary HVAC Module
    G01454481Courtesy of GENERAL MOTORS CORP.
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