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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 155 (HEATING, VENTILATION AND AIR CONDITIONING)REPAIR INSTRUCTIONSHVAC MODULE ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
2001 Chevrolet Cavalier LS, 2.4 T

Removal Procedure

2001 Chevrolet Cavalier LS, 2.4 TSECTION Removal Procedure
WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Recover the refrigerant from the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING  .
  2. Remove the battery heat shield. Refer to BATTERY HEAT SHIELD REPLACEMENT in Engine Electrical.
  3. Remove the intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT in Engine Mechanical 5.7-L.
  4. Disconnect the hose clamp and hose from the RH air injection check valve. If equipped
  5. Remove the RH air injection check valve to LH cylinder head bolt. If equipped
  6. Remove the RH air injection check valve to RH cylinder head bolts. If equipped
  7. Remove the RH air injection pipe. If equipped
    Fig 1: Removing RH Air Injection Pipe
    G01418618Courtesy of GENERAL MOTORS CORP.
  8. Remove the nut retaining the heater pipe bracket to the cowl.
    9. Fig 2: Removing Heater Pipe Bracket From Cowl
    G01418619Courtesy of GENERAL MOTORS CORP.
  9. Reposition the heater pipe bracket.
    10. Fig 3: Removing Heater Pipe To Heater Core Retaining Bolt
    G01418620Courtesy of GENERAL MOTORS CORP.
  10. Remove the heater pipe to heater core retaining bolt.

    Important:  Cap or plug the open heater pipe assembly and the heater core to prevent system contamination.

  11. Disconnect the heater pipe assembly from the heater core.
    • Allow any remaining coolant to drain
    • Remove and discard the sealing washers
    • Cap or plug the heater pipe assembly and the heater core to prevent contamination
  12. Remove the accumulator hose to evaporator retaining bolt.

    Important:  Cap or tape the A/C components immediately to prevent system contamination.

  13. Disconnect the accumulator hose and the evaporator tube - rear from the evaporator.
    • Discard the O-ring seals
    • Cap or tape the hose end, the tube end and the evaporator to prevent contamination.
    Fig 4: Removing Accumulator Hose
    G01418621Courtesy of GENERAL MOTORS CORP.
  14. Remove the HVAC module drain tube from the HVAC module.
    Fig 5: Removing HVAC Module Drain Tube From HVAC Module
    G01418622Courtesy of GENERAL MOTORS CORP.
  15. Remove the IP upper trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) UPPER in Instrument Panel, Gages and Console.
    16. Fig 6: Removing LH Side Window Defogger Outlet Duct Lower
    G01418623Courtesy of GENERAL MOTORS CORP.
  16. Remove the LH side window defogger outlet duct - lower.
    1. 16.1 Remove the push-in retainer.
    2. 16.2 Use a twisting motion to release the defogger outlet duct - lower from the windshield defroster duct, then from the defogger outlet duct - upper.
    17. Fig 7: Removing Inside Air Temperature Sensor Aspirator Duct
    G01418624Courtesy of GENERAL MOTORS CORP.
  17. Remove the inside air temperature sensor aspirator duct.
    1. 17.1 Depress the duct retaining tab and remove the duct from the ignition switch housing bracket.
    2. 17.2 Use a twisting motion to release the duct from the duct muffler.
  18. Disconnect the DRL sensor electrical connector, if equipped.
    Fig 8: Removing DRL sensor
    G01418625Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the electrical connector from the LH temperature actuator.
    Fig 9: Disconnecting Electrical Connector From LH Temperature Actuator
    G01418626Courtesy of GENERAL MOTORS CORP.
  20. Remove the IP center support bracket and the ignition switch housing bracket. Refer to BRACKET REPLACEMENT - INSTRUMENT PANEL (I/P) CENTER SUPPORT in Instrument Panel, Gages and Console.
  21. Remove the LH floor air outlet duct retaining screws.
    22. Fig 10: Removing LH Floor Air Outlet Duct
    G01418627Courtesy of GENERAL MOTORS CORP.
  22. Remove the LH floor air outlet duct.
    23. Fig 11: Removing LH Floor Air Outlet Duct (Rear)
    G01418628Courtesy of GENERAL MOTORS CORP.
  23. Remove the LH floor air outlet duct - rear.

    Rotate the duct 1/4 turn clockwise to release.

    24. Fig 12: Removing RH Side Window Defogger Outlet Duct Lower
    G01418629Courtesy of GENERAL MOTORS CORP.
  24. Remove the RH side window defogger outlet duct - lower.
    1. 24.1 Depress the defogger outlet duct - lower retaining tabs and release the duct from the passenger SIR bracket.
    2. 24.2 Use a twisting motion to release the defogger outlet duct - lower from the windshield defroster duct, then from the defogger outlet duct - upper.
  25. Remove the passenger SIR bracket and the passenger knee bolster bracket. Refer to BRACKET REPLACEMENT - KNEE BOLSTER (DRIVER)  or  BRACKET REPLACEMENT - KNEE BOLSTER (DRIVER OUTER)  or BRACKET REPLACEMENT - KNEE BOLSTER (PASSENGER) in Instrument Panel, Gages and Console.
  26. Disconnect the sunload sensor electrical connector.
  27. Disconnect the electrical connector from the RH temperature actuator.
    Fig 13: Disconnecting Electrical Connector From RH Temperature Actuator
    G01418630Courtesy of GENERAL MOTORS CORP.
  28. Remove the RH floor air outlet duct retaining screws.
  29. Remove the RH floor air outlet duct.
    Fig 14: Removing RH Floor Air Outlet Duct
    G01418631Courtesy of GENERAL MOTORS CORP.
  30. Reposition the carpet away from the RH side of the driveline tunnel to access the carpet air outlet duct.
  31. Use a rotating motion the release the carpet air outlet duct from the floor air outlet duct - rear.
    Fig 15: Releasing Carpet Air Outlet Duct From Floor Air Outlet Duct - Rear
    G01418632Courtesy of GENERAL MOTORS CORP.
  32. Remove the RH floor air outlet duct - rear.

    Rotate the duct - rear 1/4 turn counterclockwise to release.

    Fig 16: Removing RH Floor Air Outlet Duct - Rear
    G01418633Courtesy of GENERAL MOTORS CORP.
  33. Disconnect the electrical connector from the blower motor control module.
    34. Fig 17: Disconnecting Electrical Connector From Blower Motor Control Module
    G01418634Courtesy of GENERAL MOTORS CORP.
  34. Remove the blower motor. Refer to BLOWER MOTOR REPLACEMENT  .
  35. Disconnect the IP harness vacuum supply line (1) from the HVAC module vacuum harness (2).
    Fig 18: Disconnecting IP Harness Vacuum Supply Line From HVAC Module Vacuum Harness
    G01418635Courtesy of GENERAL MOTORS CORP.
  36. Disconnect the electrical connector from the vacuum electric solenoid.
    Fig 19: Disconnecting Electrical Connector From Vacuum Electric Solenoid
    G01418636Courtesy of GENERAL MOTORS CORP.
  37. Remove the windshield defroster duct retaining screws.
  38. Remove the windshield defroster duct.
    Fig 20: Removing Windshield Defroster Duct
    G01418637Courtesy of GENERAL MOTORS CORP.
  39. Remove the HVAC module retaining and sealing nuts from the cowl.

    Reposition the refrigerant lines slightly, if necessary.

  40. Remove the HVAC module retaining bolts from the IP upper support beam.
  41. Carefully remove the HVAC module from the vehicle.
    Fig 21: Removing HVAC Module
    G01418638Courtesy of GENERAL MOTORS CORP.
  42. Remove and discard the HVAC module air inlet, drain and plumbing seals.
Fig 22: Removing HVAC Module Air Inlet, Drain And Plumbing Seals
G01418639Courtesy 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.