GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Aveo 🢒 Preface 🢒 Cautions and Notices 🢒 HVAC Module Assembly Replacement

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number: 1251914 Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the instrument panel assembly. Refer to Instrument Panel Assembly Replacement in Instrument Panel, Gages, and Console.
  3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  5. Compress the heater hose clamps at the cowl and slide the clamps toward the engine.
  6. Remove the 2 heater hoses from the core lines at the cowl.
  7. Turn the condensation drain hose and pull the hose off.

    8. Object Number: 1251935 Size: SH
  8. Remove the nuts that secure the A/C suction hose and liquid evaporator pipe connector block at the cowl.

    9. Object Number: 1251940 Size: SH
  9. From the engine side of the cowl, remove the screws that secure the heater/air distribution case assembly to the cowl.
  10. Remove the heater/air distribution case assembly from the vehicle.

Installation Procedure

    Object Number: 1251940 Size: SH
  1. Clean the O-ring surface areas of dirt and contamination.
  2. Install 2 new O-rings onto the A/C suction hose and the liquid evaporator pipe at the cowl in the engine compartment.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the heater/air distribution case assembly and tighten the screws.

    4. Tighten
    Tighten the heater/air distribution case assembly retaining screws on the cowl side to 8 N·m (71 lb in).


    Object Number: 1251935 Size: SH
  4. Install the A/C suction hose and liquid evaporator pipes onto the evaporator flange connector block and tighten the nut.

    5. Tighten
    Tighten the liquid evaporator pipe connector block nut to 15 N·m (11 lb ft).


    Object Number: 1251914 Size: SH
  5. Connect the 2 heater hoses to the heater core tubes.
  6. Slide the heater hose clamps into position.
  7. Install the case condensation drain hose.
  8. Install the instrument panel assembly. Refer to Instrument Panel Assembly Replacement in Instrument Panel, Gages, and Console.
  9. Fill the cooling system.
  10. Connect the negative battery cable.
  11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  12. Operate the HVAC control to verify the proper function of the heating and cooling systems.