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HVAC Module Assembly: Removal

WARNING: This page is about a different car, the 2002 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Recover the refrigerant. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Disconnect the battery negative cable. Remove the air cleaner assembly. Remove the fuel injector sight shield (3.8L only). Drain the cooling system. Remove the Instrument Panel (I/P) trim pad. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Remove the passenger side SIR inflator module. See AIR BAG MODULES under REMOVAL & INSTALLATION in AIR BAG RESTRAINT SYSTEMS in RESTRAINTS. Remove the screw from the right and left side air distribution duct. Remove the right and left side air distribution duct. Unclip the fuse block and position aside.
  2. Remove the two screws below the fuse block that hold the main harness connector to the cross vehicle beam. Remove the brake pedal. Remove the bolts from the steering column support bracket and remove the bracket. See Fig 1. Remove the retaining bolts and position the BCM bracket aside. See Fig 2. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness out of the way.
  3. Remove the retaining bolts from the center support bracket of the HVAC module. Remove the center support bracket of the HVAC module. See Fig 3. Remove the retaining bolts from the upper support brackets of the HVAC module. See Fig 4. Remove the bolts which secure the left cross vehicle beam to the hinge pillar. See Fig 5. Remove the bolts which secure the right cross vehicle beam to the hinge pillar. See Fig 6. Remove the bolt from the cross vehicle beam. Remove the cross vehicle beam from the vehicle. See Fig 7.
  4. Remove the accumulator tube to evaporator core block fitting bolt. See Fig 8. Disconnect the accumulator tube from the evaporator. Disconnect the evaporator tube from the evaporator. Remove the O-rings seals and discard. Use Hose Clamp Pliers in order to position aside the heater hose inlet and outlet clamp at the heater core. Disconnect the inlet and outlet heater hose from the heater core. Disconnect the vacuum hoses from the HVAC module assembly. Disconnect the electrical connectors from the HVAC module assembly.
  5. Position the heater core outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly. Remove the cover screws from the heater core outlet. Remove the cover from the heater core outlet. Remove the evaporator drain elbow. Remove the nuts which secure the HVAC control assembly to the dash. See Fig 9. Remove the HVAC control assembly. Remove all of the seals from the outer HVAC control assembly.
Fig 1: Removing & Installing Steering Column Support Bracket
G00192086Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing & Installing BCM Bracket
G00192087Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing & Installing Center Support Bracket
G00192088Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing & Installing Upper Support Brackets
G00192089Courtesy of GENERAL MOTORS CORP.
Fig 5: Locating Left Cross Beam Bolts
G00192090Courtesy of GENERAL MOTORS CORP.
Fig 6: Locating Right Side Cross Beam Bolts
G00192091Courtesy of GENERAL MOTORS CORP.
Fig 7: Removing & Installing Cross Vehicle Beam
G00192092Courtesy of GENERAL MOTORS CORP.
Fig 8: Removing & Installing Evaporator Core Block Fitting
G00192093Courtesy of GENERAL MOTORS CORP.
Fig 9: Removing & Installing HVAC Module Mounting Nuts
G00192094Courtesy of GENERAL MOTORS CORP.
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