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HVAC Module: Removal

WARNING: This page is about a different car, the 2002 Saturn LW300, 2002 Saturn LW200, 2002 Saturn L300, 2002 Saturn L200, and 2002 Saturn L100. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cable. Recover refrigerant. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Measure amount of oil removed during recovery process.
    2. NOTE: Earlier vehicles used a bolt instead of a stud and nut.
  2. Remove suction/liquid line assembly to Thermal Expansion Valve (TXV) retaining nut. Remove suction/liquid line assembly block from TXV by gently rocking while pulling forward. See Fig 1 .
  3. Disconnect heater hoses from engine in order to drain remaining coolant from heater core.
    • On 2.2L models, disconnect heater inlet hose from thermostat outlet and heater return hose from block inlet. See Figure .
    • On 3.0L models, disconnect heater inlet hose from auxiliary water pump outlet and heater return hose from head bridge. See Figure .
    Place end of heater return hose in a container and apply low pressure 5 psi (34 kPa) shop air to heater inlet hose to blow coolant out of heater core.
    4. NOTE: The White line on the hoses should always be installed at the 12 o'clock position.
  4. Install heater inlet and return hoses to engine.
    • On 2.2L models, install heater inlet hose to thermostat outlet and heater return hose to thermostat inlet. Install both heater inlet hose and return hose clamps at 12 o'clock position. See Figure .
    • On 3.0L models, install heater inlet hose to auxiliary water pump outlet and heater return hose to return inlet fitting. Install clamp on heater inlet hose at 12 o'clock position and clamp on heater return hose at 3 o'clock position. See Figure .
    5. NOTE: Green plastic rings may be found hanging on pipes after hose removal, these are manufacturing aids and should be discarded.
  5. Remove heater inlet and return hoses from heater core pipes by depressing quick connect collar tab located at 6 o'clock. Pull black collar toward front of vehicle and pull quick connect off heater core pipe. See Fig 2 .
  6. Remove Instrument Panel (I/P) assembly. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
  7. For vehicles equipped with advanced audio system, remove fasteners that attach amplifier to I/P beam. Slide amplifier off clutch pedal bracket and disconnect amplifier wire harness connectors. See Fig 3 . Remove amplifier from the vehicle.
  8. Remove I/P-to-HVAC harness electrical connector from I/P beam and disconnect. Remove fasteners from "H" brace and remove "H" brace from vehicle. See Fig 4 .
  9. Remove upper intermediate shaft bolt and disconnect shaft from steering column. See Fig 5 .
  10. Remove steering column lower support bolt, upper support bolt and nut. See Fig 6 . Behind nut is a plastic locator for the steering column. This piece will center steering column in front of driver in event of an accident.
    11. NOTE: Use a T30 Torx(R) socket to prevent stripping bolt.
  11. Open drivers door completely and install a protective covering on door inner hinge area to prevent damage to paint. Using a flat-blade screwdriver, remove black plastic beam bolt covers. See Fig 7 . Using a T30 TORX(R) socket, remove both outer beam bolts. Use caution not to damage the door paint. See Fig 8 .
  12. Install Tool Flange into A-pillar beam bolt holes. See Fig 9 . Tool Flange should fit tight to the A-pillar surface when completely installed. This tool is needed to prevent accidental dropping of studs inside A-pillar. Using appropriate socket, remove both inner beam studs. See Fig 10 . Remove Flange Tool and repeat beam bolt/stud removal procedure on passenger side.
  13. Remove I/P beam to steering column brace nuts. Using a large screwdriver, pry steering column braces apart to clear I/P beam studs. See Fig 11 . Carefully remove wiring harness retainers from I/P beam. See Fig 12 . Remove I/P beam from vehicle.
  14. Open hood and remove wiper arm assemblies. See Figure .
  15. Remove weatherstrip at rear of engine compartment. Remove cowl screen retaining nuts and remove cowl assembly. See Figure .
  16. Rotate locking tabs outward to release cabin air filter assembly and remove cabin air filter by lifting straight up. See Figure .
  17. Remove wiper module retaining bolts and slide wiper module to right. See Figure . Remove cabin air filter housing attachment bolts and remove cabin air filter housing. See Figure .
  18. Remove evaporator condensate drain tube screw and remove evaporator drain tube. See Fig 13 .
  19. Remove HVAC module mounting bolts and remove HVAC module from vehicle. See Fig 14 .
Fig 1: Removing & Installing Suction/Liquid Line Assembly Block
G00223019Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing & Installing Heater Hoses At Heater Core Pipes
G00223009Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing & Installation Amplifier
G00223035Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing & Installing I/P-To-HVAC Harness Connector
G00223036Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing & Installing Upper Intermediate Shaft Bolt
G00223037Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing & Installing Steering Column
G00223038Courtesy of GENERAL MOTORS CORP.
Fig 7: Locating Outer I/P Beam Bolt Covers
G00223012Courtesy of GENERAL MOTORS CORP.
Fig 8: Removing & Installing Outer I/P Beam Bolts
G00223013Courtesy of GENERAL MOTORS CORP.
Fig 9: Installing Flange Tool
G00223014Courtesy of GENERAL MOTORS CORP.
Fig 10: Removing & Installing Inner I/P Beam Bolts
G00223015Courtesy of GENERAL MOTORS CORP.
Fig 11: Removing & Installing Steering Column Brace Nuts
G00223016Courtesy of GENERAL MOTORS CORP.
Fig 12: Removing & Installing Wiring Harness At I/P Beam
G00223039Courtesy of GENERAL MOTORS CORP.
Fig 13: Removing & Installing Evaporator Drain
G00223010Courtesy of GENERAL MOTORS CORP.
Fig 14: Removing & Installing HVAC Module
G00223011Courtesy of GENERAL MOTORS CORP.
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