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Home >> GMC >> 2003 >> Jimmy 2D Utility, Part Time, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Heating, Ventilation And Air Conditioning) >> Repair Instructions >> HVAC Module Assembly Replacement >> Installation Procedure
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Installation Procedure

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: HVAC Module, Bolts & Cross Car Beam
    GM933686Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure seals on HVAC module are flush and even as the meet their mating surfaces. This will reduce the chance of leaks and insure proper fit.
  1. Check front of dash seal for proper alignment.
  2. Check seal mating surfaces to insure there are no obstructions.
    3. IMPORTANT: Make sure center "molded in case" HVAC to cross car beam bracket is forward of cross car beam down flange.
  3. Loose hang HVAC module from cross car beam.
    4. Fig 2: HVAC Module Seal & Nuts
    GM931912Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: New front of dash seal nuts must be used to prevent leaks.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install front of dash to HVAC module seal nuts, draw module to FOD evenly with nuts and tighten.

    Tighten:  Tighten the nuts to 8 N.m (71 lb in).

    5. Fig 3: Metal Bracket & Nut
    GM933704Courtesy of GENERAL MOTORS CORP.
  5. Push up on HVAC module at blower motor area while tightening right side HVAC module to cross car beam fasteners (to seat screen assembly/fresh air seal).

    Tighten:  Tighten the fasteners to 8 N.m (71 lb in).

  6. Install the left HVAC module to cross car beam stamped metal L-type bracket to HVAC module and cross car beam and tighten remaining module attachment fasteners.

    Tighten:  Tighten the fasteners to 8 N.m (71 lb in).

  7. Connect I/P wire harness clips to HVAC module.
    8. Fig 4: Defroster Duct & Retainer
    GM932519Courtesy of GENERAL MOTORS CORP.
  8. Install defroster duct to HVAC module nuts and defroster duct.

    Tighten:  Tighten the nuts to 2.5 N.m (22 lb in).

    9. Fig 5: Blower Motor Electrical Connector & I/P Wire Harness
    GM932498Courtesy of GENERAL MOTORS CORP.
  9. Connect I/P harness to blower motor connector.
  10. Connect I/P harness to blower motor resistor connector.
  11. Connect I/P harness to HVAC module connector.
    12. Fig 6: Center I/P Air Outlet Duct & Retainers
    GM931922Courtesy of GENERAL MOTORS CORP.
  12. Install auxiliary duct assembly.
    13. Fig 7: Center Floor Air Outlet Duct
    GM933579Courtesy of GENERAL MOTORS CORP.
  13. Install front rear duct by sliding forward on heater duct then down and rearward over rear duct.
  14. Install the shift control bracket. Refer to Transmission Shift Control Bracket Replacement in Manual Transmission - Getrag 5, Transmission Shift Control Bracket Replacement in Automatic Transaxle - AF33-5.
  15. Install the I/P retainer. Refer to Instrument Panel (I/P) Retainer Replacement in Instrument Panel, Gages, and Console.
    16. Fig 8: Heater Inlet, Hose Clamp & Heater Core
    GM931806Courtesy of GENERAL MOTORS CORP.
  16. Install heater inlet hose to heater core inlet.
  17. Position the clamp at 9 o'clock using SA9111E  . See Special Tools .
    18. Fig 9: Heater Outlet, Hose Clamp & Heater Core
    GM931798Courtesy of GENERAL MOTORS CORP.
  18. Install heater outlet hose to heater core outlet.
  19. Position the clamp at 9 o'clock position using SA9111E  . See Special Tools .
    20. Fig 10: Liquid Line, Nut & TXV
    GM931930Courtesy of GENERAL MOTORS CORP.
  20. Insure mating surfaces are clean and free of debris, and install a new seal washer to the liquid line. Refer to Sealing Washer Replacement .
  21. Install the liquid line and nut to the thermal expansion valve (TXV).

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

    22. Fig 11: Compressor Hose, Nut & TXV
    GM931940Courtesy of GENERAL MOTORS CORP.
  22. Insure mating surfaces are clean and free of debris, and install a new seal washer to the suction hose. Refer to Sealing Washer Replacement .
  23. Install the suction hose and nut to the thermal expansion valve (TXV).

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

  24. Enable the frontal and curtain air bags. Refer to DISABLING & ACTIVATING AIR BAG SYSTEM .
  25. Fill the coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
  26. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  27. Leak test the fittings using the J 39400-A  . See Special Tools .
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