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Installation Procedure

WARNING: This page is about a different car, the 2003 Chevrolet Monte Carlo and 2003 Chevrolet Impala. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Locating HVAC Module Assembly Seals
    GM283719Courtesy of GENERAL MOTORS CORP.
  1. Install new seals (1,2,3) to the outer HVAC control module.
    2. IMPORTANT: When installing the HVAC control module, ensure that the dash insulator pad cut-outs and the HVAC seals, studs, and drain align and seal properly to the dash panel.
  2. Install the HVAC control module into the vehicle:
    1. Align the heater core outlet cover to the rear floor air outlet duct.
    2. Roll the HVAC control module forward and upward and align the dash insulator pad to the recirculation opening of the HVAC control module.
    3. Align the mounting studs and the drain on the HVAC control module to seat against the dash panel.
    3. Fig 2: HVAC Module Assembly To Dash Nuts
    GM507700Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the nuts which secure the HVAC control module to the dash.

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

    4. Fig 3: View Of Evaporator Drain Elbow
    GM282300Courtesy of GENERAL MOTORS CORP.
  4. Install the evaporator drain elbow.
  5. Connect the vacuum hoses to the HVAC control module.
  6. Connect the electrical connectors to the HVAC control module.
    7. Fig 4: Cross Vehicle Beam
    GM558194Courtesy of GENERAL MOTORS CORP.
  7. Install the cross vehicle beam to the vehicle.
    8. Fig 5: Cross Vehicle Beam & Bolts
    GM812572Courtesy of GENERAL MOTORS CORP.
  8. Install the bolts to the right and left side of the cross vehicle beam.
  9. Tighten the bolts to the right and left side of the cross vehicle beam in sequence.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    10. Fig 6: HVAC Module Upper Support
    GM558113Courtesy of GENERAL MOTORS CORP.
  10. Install the bracket bolts to the HVAC module upper support.

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

  11. Install the passenger knee bolster bracket. Refer to Knee Bolster Bracket Replacement - Right in Instrument Panel, Gages, and Console.
    12. Fig 7: HVAC Module Center Support & Bolts
    GM558111Courtesy of GENERAL MOTORS CORP.
  12. Install the bracket to the HVAC module center support.
  13. Install the bolts to the HVAC module center support.
  14. Reposition the vacuum harness to the original position.
  15. Tighten the bolts in sequence as shown.

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

  16. Reposition the IP wiring harness on to the cross vehicle beam and secure the retaining clips.
  17. Install the 3 bolts through the brake pedal bracket to the cross vehicle beam.

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

  18. Install the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  19. Connect all disconnected ground wires.
  20. Install the body control module.
  21. Install the left side fuse block to the cross vehicle beam.
  22. Install the steering column. Refer to Steering Column Replacement in Steering Wheel and Column.
    23. Fig 8: Right Air Distribution Duct & Retaining Bolts
    GM507699Courtesy of GENERAL MOTORS CORP.
  23. Install the right air duct to the cross vehicle beam.
  24. Install the right air duct bolts.

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

    25. Fig 9: Panel Air Duct, Retaining Screw & Retaining Bolts
    GM812951Courtesy of GENERAL MOTORS CORP.
  25. Install the panel air duct to the cross vehicle beam.
  26. Install the panel air duct screw (1).

    Tighten:  Tighten the screw to 1.8 N.m (16 lb in).

  27. Install the panel air duct bolts.

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

  28. Install the IP lower trim panel. Refer to Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala) or Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo) in Instrument Panel, Gages, and Console.
    29. Fig 10: View Of Heater Inlet Hose At Heater Core
    GM415886Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Reposition the heater core hose clamps in the indicated location.
  29. Connect the inlet and outlet heater hose to the heater core.
  30. UseJ 38185  in order to reposition the heater hose inlet and outlet clamp to the heater core.
  31. Install new O-rings seals on the evaporator tube and accumulator tube. Refer to O-Ring Replacement .
    32. Fig 11: A/C Line Block Fitting Bolt At Evaporator
    GM532742Courtesy of GENERAL MOTORS CORP.
  32. Connect the evaporator tube to the evaporator.
  33. Connect the accumulator tube to the evaporator.
  34. Install the accumulator tube to evaporator core block fitting bolt.

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

  35. Install the cross vehicle brace. Refer to Brace Replacement - Cross Vehicle in Body Front End.
  36. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  37. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  38. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  39. Leak test the fittings of the component using J 39400-A  . See Special Tools .
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