GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Cavalier 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 HVAC Module Assembly Replacement

Removal Procedure
  1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  3. Disconnect the evaporator lines from the evaporator.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Disconnect the heater hoses at the heater core.
  6. Lower the vehicle.
  7. Remove the evaporator case drain tube.
  8. Remove the inside and outside module attaching bolts and the accumulator mounting bracket bolt.
  9. Remove the following components:
    10. • The instrument panel; For Chevrolet or Pontiac vehicles, refer to Instrument Panel Carrier Replacement .
    • The instrument panel tie bar; For Chevrolet or Pontiac vehicles, refer to Instrument Panel Tie Bar Replacement
  10. Remove the floor air outlet.
  11. Disconnect the wiring harness from the module.
  12. Disconnect the electrical connections at the following locations:
    13. • The blower motor
    • The blower resistor
  13. Remove the module from the vehicle.

Installation Procedure
  1. Install the module in the vehicle.
  2. Connect the electrical connections at the following locations:
    3. • The blower motor
    • The blower resistors
  3. Connect the wiring harness to the module.
  4. Install the floor air outlet.
  5. Install the following components:
    6. • The instrument panel; For Chevrolet or Pontiac vehicles, refer to Instrument Panel Carrier Replacement .
    • The instrument panel tie bar; For Chevrolet or Pontiac vehicles, refer to Instrument Panel Tie Bar Replacement

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6. Install the upper module attaching bolts.

    7. Tighten
    Tighten the bolts to 2 N·m (18 lb in).

  7. Install the lower module attaching bolts.

    8. Tighten
    Tighten the bolts to 2 N·m (18 lb in).

  8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  9. Install the evaporator case drain tube.
  10. Connect the heater hoses to the heater core.
  11. Lower the vehicle.
  12. Connect the evaporator lines to the evaporator.

    13. Tighten
    Tighten the fittings to 24 N·m (18 lb ft).

  13. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging .
  14. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.