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Revised HVAC Module Assembly Replacement (W/Air Conditioning)

Subject:Revised HVAC Module Assembly Replacement (W/Air Conditioning)

Models:2004-2005 Chevrolet Colorado Crew Cab Models
2004-2005 GMC Canyon Crew Cab Models
With Air Conditioning


This bulletin is being issued to revise the HVAC Module Assembly Replacement (W/Air Conditioning) procedure in the Heating, Ventilation and Air Conditioning sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information.

The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page.

HVAC Module Assembly Replacement (W/Air Conditioning)

Tools Required

    • J 43181 Heater Line Quick Connect Release Tool
    • J 39400-A Halogen Leak Detector

Removal Procedure

  1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  3. Remove the instrument panel (I/P) carrier. Refer to Instrument Panel (I/P) Carrier Replacement in Instrument Panel, Gages, and Console.

    4. Object Number: 1222554 Size: SH
  4. Release the heater hose clamps using J 43181.
  5. Disconnect the heater hose quick connects (2) and (3) from the heater core.

    6. Object Number: 872539 Size: SH
  6. Remove the retaining nut from the TXV stud.
  7. Remove the evaporator tube and suction hose from the TXV.
  8. Remove the radio antenna from the HVAC module.
  9. Reposition the carpet.
  10. Remove rear floor duct. Refer to Air Outlet Replacement - Rear Floor.
  11. Remove the HVAC module retaining nuts from the cowl.
  12. Remove the HVAC module assembly.

Installation Procedure

  1. Install the HVAC module assembly.
  2. Install the HVAC module retaining nuts from the cowl.

    3. Notice: Refer to Fastener Notice .

  3. Tighten the HVAC module retaining nuts.

    4. Tighten
    Tighten the nut to 4.5 N·m (40 lb in).


    Object Number: 872539 Size: SH
  4. If replacing the HVAC module assembly (8), transfer the components from the old HVAC module assembly as necessary.
  5. Install the HVAC module assembly (8).
  6. Install rear floor duct. Refer to Air Outlet Replacement - Rear Floor.
  7. Reposition the carpet.
  8. Install the radio antenna to the HVAC module.

    9. Object Number: 1222554 Size: SH
  9. Connect the heater hose quick connects (2) and (3) to the heater core.
  10. Install the evaporator tube and suction hose to the TXV.
  11. Install the retaining nut to the TXV stud.
  12. Tighten the retaining nut.

    13. Tighten
    Tighten the nut to 4.5 N·m (40 lb in).

  13. Install the I/P carrier. Refer to Instrument Panel (I/P) Carrier Replacement in Instrument Panel, Gages and Console.
  14. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
  15. Leak test the fittings of the components using the J 39400-A .
  16. Refill the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.