LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Pontiac >> 2003 >> Aztek AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 20 (HVAC Systems - Manual) >> Removal & Installation >> HVAC Module Assembly >> Removal
April 5, 2026: LEMON Manuals is launched! Read the announcement.

HVAC Module Assembly: Removal

WARNING: This page is about a different car, the 2002 Buick Regal and 2002 Buick Century. 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. Remove the underhood cross vehicle brace. Drain the cooling system. Remove the fuel injector sight shield (3.8L only).
  2. Remove the instrument panel trim pad. See TRIM PAD REPLACEMENT - I/P in ACCESSORIES & EQUIPMENT. Remove the passenger side SIR inflator module. See AIR BAG MODULES under REMOVAL & INSTALLATION in AIR BAG RESTRAINT SYSTEMS in RESTRAINTS.
  3. Remove the brake pedal. Remove the bolts from the steering column support bracket and remove the bracket. See Fig 1. Remove the screw from the right and left side air distribution duct. Remove the right and left side air distribution duct. Remove the bolts from the relay bracket and position the relay bracket aside.
  4. Remove the bolts from the BCM bracket 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 aside. Remove the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam. Remove the bolts from the center support bracket of the HVAC module. See Fig 3.
  5. Remove the center support bracket of the HVAC module. Remove the 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. See Fig 7. Remove the cross vehicle beam from the vehicle.
  6. 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-ring seals and discard. Use J-38185 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.
    7. NOTE: Position the heater core outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly.
  7. Remove the screws from the heater core outlet cover. Remove the heater core outlet cover. Remove the evaporator drain elbow. Remove the mounting nuts for the HVAC module assembly from the cowl. See Fig 9.
  8. Disconnect the vacuum hoses from the HVAC module assembly. Disconnect the electrical connectors from the HVAC module assembly. Remove the HVAC module 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.
scientia non olet · About LEMON Manuals