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HOMESERVICE MANUALSCHEVROLET1999PICKUP K1500, 5.7 RREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 449 (HEATING, VENTILATION AND AIR CONDITIONING)REPAIR INSTRUCTIONSHVAC MODULE ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
1999 Chevrolet Pickup K1500, 5.7 R

Installation Procedure

1999 Chevrolet Pickup K1500, 5.7 RSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.

Important:  Ensure proper alignment of the HVAC module assembly and HVAC module drain through the cowl.

  1. Install the HVAC module assembly to the cowl.
  2. Install the HVAC module assembly to dash panel sound barrier nuts.

    Do not tighten the HVAC module assembly nuts at this time.

  3. Install the heater outlet hose to the heater core. Refer to HEATER HOSE REPLACEMENT - OUTLET  .
  4. Install the heater inlet hose to the heater core. Refer to HEATER HOSE REPLACEMENT - INLET  .
    Fig 1: Installing HVAC Module Assembly To cowl
    G01498896Courtesy of GENERAL MOTORS CORP.
  5. Install new sealing washers to the evaporator inlet and outlet tubes. Refer to SEALING WASHER REPLACEMENT  .
  6. Connect the evaporator inlet tube to the evaporator outlet tube.
  7. Connect the evaporator inlet and outlet tubes to the TXV.
  8. Install the evaporator outlet tube nut at the TXV.

    Tighten 

    Tighten the nut to 16 N.m (12 lb ft).

    Fig 2: Installing New Sealing Washers To Evaporator Inlet And Outlet Tubes
    G01498897Courtesy of GENERAL MOTORS CORP.
  9. Install the I/P carrier. Refer to INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT .
  10. Connect all of the HVAC electrical actuator connectors.
  11. Connect the electrical connector to the evaporator temperature sensor.
    Fig 3: Connecting Electrical Connector To Blower Motor Resistor
    G01498898Courtesy of GENERAL MOTORS CORP.
  12. Connect the electrical connector to the blower motor resistor.
  13. Install the blower motor. Refer to BLOWER MOTOR REPLACEMENT 
    Fig 4: Connecting Electrical Connector To Blower Motor Resistor
    G01498899Courtesy of GENERAL MOTORS CORP.
  14. Tighten the HVAC module assembly to dash panel sound barrier nuts.

    Tighten 

    Tighten the nuts to 10 N.m (89 lb in).

  15. Install the wiper motor module assembly. Refer to WIPER MOTOR MODULE REPLACEMENT .
  16. Fill the coolant system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  17. Evacuate and recharge the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING 
  18. Leak test the fittings of the component using the J 39400-A  .
    Fig 5: Tightening HVAC Module Assembly To Dash Panel Sound Barrier Nuts
    G01498900Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.