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Revised Heater/Vent Module Replacement (02-01-38-005)

Publication date: 2002-12-01
Reference number: 02-01-38-005

REVISED HEATER/VENT MODULE REPLACEMENT

REVISED HEATER/VENT MODULE REPLACEMENT

TECHNICAL SERVICE BULLETIN

Reference Number(s): 02-01-38-005, Date of Issue:  December 1, 2002
CHEVROLET: 1998-2002 Blazer, S10
GMC: 1998-2002 Jimmy, Sonoma
OLDSMOBILE: 1998-2002 Bravada
SECTION: 01 - HVAC

SERVICE INFORMATION

This bulletin is being issued to revise the Heater/Vent Module Replacement procedure in the Heating, Ventilation and Air Conditioning sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information.

The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page.

REMOVAL PROCEDURE

  1. Remove the instrument panel. Refer to Instrument Panel (I/P) Carrier Replacement in Instrument Panel, Gages and Console. Refer to Fig 1 .
    Fig 1: Removing I/P
    G00273921
  2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
  3. Remove the blower motor resistor. Refer to Blower Motor Resistor Assembly Replacement. See Fig 2 .
    Fig 2: Removing Blower Motor Resistor
    G00273922
    IMPORTANT: Mark and use the same mounting bolt for the heater/vent module during the installation process. Other mounting bolts are longer and will obstruct the operation of the temperature door.
  4. Remove the heat/vent module mounting bolt through the blower motor resistor or service access cover opening.
  5. Remove the right wheel house panel. Refer to Wheelhouse Panel Replacement in Body Front End. Refer to Fig 3 .
    Fig 3: Removing Right Wheel House Panel
    G00273924
  6. Remove the front right tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  7. On the Utility only, remove the A/C evaporator and blower module heat shield screws.
  8. On the Utility only, slide the A/C evaporator and blower module heat shield toward the front of the vehicle.
  9. Remove the 2 lower heat/vent module mounting nuts.
  10. On the Utility only, remove the A/C evaporator and blower module heat shield bracket.
  11. Remove the bottom right heat/vent module mounting bolt from inside the vehicle.
    IMPORTANT: The heat/vent mounting stud has a flange on the inside and cannot be removed from under the hood. Stop turning the stud after the threads are off the heat/vent module.
  12. On the Utility only, while an assistant inside the vehicle pulls the bottom right corner of the heat/vent module approximately 2.5 mm (1 in) back, remove the 2 heat/vent module mounting studs.
  13. Lower the vehicle.
  14. On vehicles with a 2.2 L engine only, remove the engine wiring harness bracket located at the rear of the intake manifold. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical - 2.2 L.
  15. Remove the HVAC module mounting bolt located at the lower left side of the heater core to heater hose connection. See Fig 4 .
    Fig 4: Removing HVAC Module
    G00273923
  16. Remove the HVAC module mounting nut located at the lower right side of the heater core to heater connection.
    IMPORTANT: The heat/vent mounting stud has a flange on the inside and cannot be removed from under the hood. Stop turning the stud after the threads are off the heat/vent module.
  17. On the Utility only, loosen the HVAC module mounting studs until the threads are free from the heat/vent module.
  18. Disconnect all of the electrical connectors from the HVAC module.
  19. Disconnect all of the vacuum lines from the heater assembly.
  20. Disconnect the heater hoses from the heater core.
  21. Remove the HVAC module from the vehicle.

INSTALLATION PROCEDURE

  1. If replacing the HVAC module, transfer the components from the old heat/vent module as necessary. Refer to Fig 4 .
    IMPORTANT: Before installing the HVAC module to the vehicle, ensure that the HVAC module mounting studs are located in the proper positions.
  2. Install the HVAC module to the vehicle.
  3. Connect the heater hoses to the heater core.
  4. Connect all of the vacuum lines to the heater assembly.
  5. Connect all of the electrical connectors to the HVAC module.
  6. Install the bottom right HVAC module mounting bolt from inside the vehicle approximately halfway into the threads.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. On the Utility only, install the HVAC module mounting stud located at the lower right side of the heater core to heater hoses connection in the engine compartment. Tighten the HVAC module mounting stud to 4.5 N.m (40 lb-in).
  8. Raise the vehicle.
  9. On the Utility only, install the bottom right HVAC mounting studs. Ask an assistant to pull the bottom right corner of the HVAC module back from inside the vehicle. Tighten the heat/vent module mounting studs to 4.5 N.m (40 lb-in).
  10. On the Utility only, install the A/C evaporator and blower module heat shield bracket.
  11. Install the heater/vent module mounting nuts. Tighten the HVAC module mounting nuts to 4.5 N.m (40 lb-in).
  12. On the Utility only, slide the A/C evaporator and blower module heat shield into the original position.
  13. On the Utility only, install the A/C evaporator and blower module heat shield screws. Tighten the A/C evaporator and blower module heat shield screws 2.2 N.m (19 lb-in). See Fig 3 .
  14. Install the right front tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  15. Install the bottom right HVAC module mounting bolt from inside the vehicle. Tighten the HVAC module mounting bolt to 4.5 N.m (40 lb-in).
  16. Install the right wheel house panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  17. Install the HVAC module mounting nut located at the lower right side of the heater core to heater connection. Tighten the HVAC module mounting nut to 4.5 N.m (40 lb-in). See Fig 4 .
  18. Install the HVAC module mounting bolt located at the lower left side of the heater core to heater hose connection. Tighten the HVAC module mounting bolt to 4.5 N.m (40 lb-in).
  19. On vehicles with the 2.2 L engine only, install the engine wiring harness bracket located at the rear of the intake manifold. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical - 2.2 L.
    IMPORTANT: Use the same mounting bolt marked during removal for the HVAC module during the installation process. Other mounting bolts are longer and will obstruct the operation of the temperature door.
  20. Install the HVAC module mounting bolt through the blower motor resistor or service access cover opening. Tighten the HVAC module mounting bolt to 4.5 N.m (40 lb-in).
  21. Install the blower motor resistor. Refer to Blower Motor Resistor Assembly Replacement. Refer to Fig 2 .
  22. Refill the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
  23. Install the instrument panel. Refer to Instrument Panel (I/P) Carrier Replacement in Instrument Panel, Gages and Console.
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