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Revised HVAC Module Assembly Replacement (06-01-37-002)

WARNING: This page is about the Grand Am GT, 2D Coupe, 2.2 F, which is a different variant/trim than selected.
Publication date: 2006-01-18
Reference number: 06-01-37-002

Revised HVAC Module Assembly Replacement

Revised HVAC Module Assembly Replacement

TECHNICAL SERVICE BULLETIN

Reference Number(s): 06-01-37-002, Date of Issue:  January 18, 2006
Affected Model(s): 2002-2004 Chevrolet Alero (Export); 2002-2004 Oldsmobile Alero; 2002-2005 Pontiac Grand Am

SERVICE INFORMATION

This bulletin is being issued to revise the HVAC Module Assembly 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.

HVAC Module Assembly Replacement

Tools Required 

J 39400-A Halogen Leak Detector

Removal Procedure

  1. Disconnect the negative battery cable. Refer to Battery Replacement in Engine Electrical.
  2. Recover the A/C system. Refer to Refrigerant Recovery and Recharging.
  3. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
  4. Raise and support the vehicle. Refer to Lifting and Jacking Vehicle in General Information.
    5. Fig 1: Evaporator Hose Assembly
    GM590061Courtesy of GENERAL MOTORS CORP.
  5. Remove the evaporator hose assembly nut from the evaporator.
  6. Remove the evaporator hose assembly from the evaporator.
  7. Remove and discard the seal washers.
    8. Fig 2: Heater Hose
    GM790922Courtesy of GENERAL MOTORS CORP.
  8. Remove the inlet heater hose from the heater core.
  9. Remove the outlet heater hose from the heater core.
    10. Fig 3: Drain Tube Elbow
    GM588295Courtesy of GENERAL MOTORS CORP.
  10. Remove the drain tube elbow from the evaporator block heater case plate.
    11. Fig 4: Heater Case Plate
    GM588299Courtesy of GENERAL MOTORS CORP.
  11. Remove the nuts holding the heater case plate for the heater pipes.
  12. Remove the heater case plate and the seals for the heater pipes.
  13. Remove the nuts holding the heater case plate for the evaporator block.
  14. Remove the heater case plate and seal for the evaporator block.
  15. Remove the nut for the HVAC module assembly bracket.
  16. Lower the vehicle.
  17. Remove the air distribution duct. Refer to Air Distribution Duct Replacement.
  18. Remove the floor air duct from the HVAC module assembly. Refer to Air Outlet Replacement - Floor.
    19. IMPORTANT: Note the routing of the wiring harness to ensure proper installation.
  19. Disconnect the wiring harness from the cross vehicle beam.
  20. Remove the steering column. Refer to Steering Column Replacement in Steering Wheel and Column.
    21. Fig 5: Cross Vehicle Beam Retaining Bolts
    GM1745422Courtesy of GENERAL MOTORS CORP.
  21. Remove the bolts retaining the cross vehicle beam to the steering column support bracket.
    22. Fig 6: HVAC Module Center Support Bracket
    GM282301Courtesy of GENERAL MOTORS CORP.
  22. Remove the HVAC module center support bracket.
    23. Fig 7: HVAC Module Bracket
    GM291493Courtesy of GENERAL MOTORS CORP.
  23. Remove the bolts from the bracket joining the cross vehicle beam to the HVAC module (3).
    24. Fig 8: LH Hinge Pillar
    GM1745423Courtesy of GENERAL MOTORS CORP.
  24. Remove the bolts retaining the cross vehicle beam to the LH hinge pillar.
    25. Fig 9: RH Hinge Pillar
    GM1745425Courtesy of GENERAL MOTORS CORP.
  25. Remove the bolt and nut retaining the cross vehicle beam to the RH hinge pillar.
    26. Fig 10: Beam to Cowl
    GM1745427Courtesy of GENERAL MOTORS CORP.
  26. Remove the bolts retaining the cross vehicle beam to the cowl.
    27. Fig 11: Cross Vehicle Beam
    GM291494Courtesy of GENERAL MOTORS CORP.
  27. Remove the cross vehicle beam from the vehicle (1).
    28. Fig 12: DRL Sensor Wiring Harness Clip
    GM590288Courtesy of GENERAL MOTORS CORP.
  28. Remove the daytime running lights (DRL) sensor wiring harness clip (1) from the HVAC module assembly.
  29. Disconnect the I/P lamp dimmer switch electrical connector (2).
  30. Remove the wiring harness clips (3) from the HVAC module assembly bracket.
  31. Disconnect the vacuum hose (4) from the vacuum tank.
    32. Fig 13: Blower Motor Resistor
    GM588308Courtesy of GENERAL MOTORS CORP.
  32. Disconnect the blower motor resistor electrical connector.
  33. Disconnect the blower motor electrical connector.
    34. Fig 14: Temperature Actuator
    GM590302Courtesy of GENERAL MOTORS CORP.
  34. Disconnect the temperature actuator electrical connector.
    35. Fig 15: HVAC Module Assembly
    GM592637Courtesy of GENERAL MOTORS CORP.
  35. Remove the HVAC module assembly.

Installation Procedure

    Fig 16: HVAC Module Assembly
    GM592637Courtesy of GENERAL MOTORS CORP.
  1. Position the HVAC module assembly to the vehicle.
    2. Fig 17: Temperature Actuator
    GM590302Courtesy of GENERAL MOTORS CORP.
  2. Connect the temperature actuator electrical connector.
    3. Fig 18: Blower Motor Resistor
    GM588308Courtesy of GENERAL MOTORS CORP.
  3. Connect the blower motor resistor electrical connector.
  4. Connect the blower motor electrical connector.
    5. Fig 19: DRL Sensor Wiring Harness Clip
    GM590288Courtesy of GENERAL MOTORS CORP.
  5. Install the wiring harness clips (3) to the HVAC module assembly bracket.
  6. Install the daytime running lights (DRL) sensor wiring harness clip (1) from the HVAC module assembly.
  7. Connect the I/P lamp dimmer switch electrical connector (2).
  8. Install the vacuum hose (4) to the vacuum tank.
    9. Fig 20: Cross Vehicle Beam
    GM291494Courtesy of GENERAL MOTORS CORP.
  9. Position the cross vehicle beam (1) to the hinge pillar.
    10. Fig 21: RH Hinge Pillar
    GM1745425Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not tighten bolts until step 14.
  10. Install the cross vehicle beam to the RH hinge pillar retaining bolt and nut; do not tighten.
    11. Fig 22: Beam to Cowl
    GM1745427Courtesy of GENERAL MOTORS CORP.
  11. Install the cross vehicle beam to cowl retaining bolts.
    12. Fig 23: Cross Vehicle Beam Retaining Bolts
    GM1745422Courtesy of GENERAL MOTORS CORP.
  12. Install the cross vehicle beam to steering column bracket retaining bolt.
    13. Fig 24: HVAC Module Bracket
    GM1745423Courtesy of GENERAL MOTORS CORP.
  13. Install the cross vehicle beam to the LH hinge pillar retaining bolts.
    NOTE: Refer to Fastener Notice.
  14. Tighten the bolts and nut retaining the cross vehicle beam to the vehicle.

    Tighten:  

    • Hinge pillar bolts and nut 20 N.m (15 lb ft).
    • Cross vehicle beam to cowl 10 N.m (89 lb in).
    • Cross vehicle beam to steering column bracket 20 N.m (15 lb ft).

    15. Fig 25: Cross Vehicle Beam Retaining Bolts
    GM482597Courtesy of GENERAL MOTORS CORP.
  15. Install the HVAC module to the cross vehicle beam retaining bolts.

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

    16. Fig 26: HVAC Module Center Support Bracket
    GM282301Courtesy of GENERAL MOTORS CORP.
  16. Install the HVAC module center support bracket.
  17. Install the HVAC module center support bracket retaining bolts.

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

  18. Install the steering column. Refer to Steering Column Replacement in Steering Wheel and Column.
  19. Install the instrument panel wiring harness into position and secure the retaining clips.
  20. Install the floor air duct to the HVAC module assembly. Refer to Air Outlet Replacement - Floor.
  21. Install the air distribution duct. Refer to Air Distribution Duct Replacement.
  22. Raise the vehicle.
  23. Install the nut for the HVAC module assembly bracket.

    Tighten:   Tighten the bracket nut to 10 N.m (88 lb in).

    24. Fig 27: Heater Core Case Plate
    GM588299Courtesy of GENERAL MOTORS CORP.
  24. Install the heater core case plate and the seals for the heater pipes.
  25. Install the nuts holding the heater core case plate for the heater pipes.
  26. Install the heater core case plate and seal for the evaporator block.
  27. Install the nuts holding the heater core case plate for the evaporator block.

    Tighten:   Tighten the nuts to 10 N.m (88 lb in).

    28. Fig 28: Drain Tube Elbow
    GM588295Courtesy of GENERAL MOTORS CORP.
  28. Install the drain tube elbow to the heater core case plate for the evaporator block.
    29. Fig 29: Evaporator Hose Assembly
    GM590061Courtesy of GENERAL MOTORS CORP.
  29. Install new sealing washers.
  30. Install the evaporator hose to the evaporator.
  31. Install the evaporator hose nut to the evaporator.

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

    32. Fig 30: Heater Hose
    GM790922Courtesy of GENERAL MOTORS CORP.
  32. Install the outlet heater hose to the heater core.
  33. Install the inlet heater hose to the heater core.
  34. Lower the vehicle.
  35. Connect the negative battery cable. Refer to Battery Replacement in Engine Electrical.
  36. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  37. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
  38. Leak test the fittings of the component using the J 39400-A .
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