SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 737 (HEATING, VENTILATION AND AIR CONDITIONING)REPAIR INSTRUCTIONSHVAC MODULE ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8

Removal Procedure

2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8SECTION Removal Procedure
WARNING: This page is about a different car, the 2004 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. Fig 1: RH Air Injection Check Valve To RH/LH Cylinder Head & Bolts
    GM63229Courtesy of GENERAL MOTORS CORP.
  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
    8. Fig 2: Heater Pipe Bracket & Cowl
    GM621749Courtesy of GENERAL MOTORS CORP.
  8. Remove the nut retaining the heater pipe bracket to the cowl.
  9. Reposition the heater pipe bracket.
    10. Fig 3: Heater Core, Retaining Bolt & Heater Pipe
    GM621745Courtesy of GENERAL MOTORS CORP.
  10. Remove the heater pipe to heater core retaining bolt.
    11. 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. Fig 4: Accumulator Hose, Evaporator & Bolt
    GM621748Courtesy of GENERAL MOTORS CORP.
  12. Remove the accumulator hose to evaporator retaining bolt.
    13. 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.
    14. Fig 5: HVAC Module Drain Tube & I/P Upper Trim Pad
    GM621744Courtesy of GENERAL MOTORS CORP.
  14. Remove the HVAC module drain tube from the HVAC module.
  15. Remove the I/P upper trim pad. Refer to Trim Pad Replacement - Instrument Panel (I/P) Upper in Instrument Panel, Gages and Console.
    16. Fig 6: LH Side Window Defogger & Lower Outlet Duct
    GM95655Courtesy of GENERAL MOTORS CORP.
  16. Remove the LH side window defogger outlet duct - lower.
    1. Remove the push-in retainer.
    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: Inside Air Temperature Sensor Aspirator Duct
    GM95661Courtesy of GENERAL MOTORS CORP.
  17. Remove the inside air temperature sensor aspirator duct.
    1. Depress the duct retaining tab and remove the duct from the ignition switch housing bracket.
    2. Use a twisting motion to release the duct from the duct muffler.
    18. Fig 8: DRL Sensor Electrical Connector
    GM95644Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the DRL sensor electrical connector, if equipped.
    19. Fig 9: Locating Actuator Connector
    GM295297Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the electrical connector from the LH temperature actuator.
    20. Fig 10: LH Floor Air Outlet Duct & Retaining Screws
    GM95646Courtesy of GENERAL MOTORS CORP.
  20. Remove the I/P 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. Remove the LH floor air outlet duct.
    23. Fig 11: Rear LH Floor Air Outlet Duct
    GM95652Courtesy 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: RH Side Window Defogger & Lower Outlet Duct
    GM95658Courtesy of GENERAL MOTORS CORP.
  24. Remove the RH side window defogger outlet duct - lower.
    1. Depress the defogger outlet duct - lower retaining tabs and release the duct from the passenger SIR bracket.
    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 (Passenger) or Bracket Replacement - Knee Bolster (Driver) or Bracket Replacement - Knee Bolster (Driver Outer) in Instrument Panel, Gages and Console.
  26. Disconnect the sunload sensor electrical connector.
    27. Fig 13: RH Temperature Actuator & Electrical Connector
    GM295333Courtesy of GENERAL MOTORS CORP.
  27. Disconnect the electrical connector from the RH temperature actuator.
    28. Fig 14: RH Floor Air Outlet Duct & Screws
    GM95647Courtesy of GENERAL MOTORS CORP.
  28. Remove the RH floor air outlet duct retaining screws.
  29. Remove the RH floor air outlet duct.
    30. Fig 15: RH Side Driveline Tunnel & Carpet Air Outlet Duct
    GM297307Courtesy 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.
    32. Fig 16: Rear RH Floor Air Outlet Duct
    GM95654Courtesy of GENERAL MOTORS CORP.
  32. Remove the RH floor air outlet duct - rear.

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

    33. Fig 17: Blower Motor Control Module & Electrical Connector
    GM295319Courtesy of GENERAL MOTORS CORP.
  33. Disconnect the electrical connector from the blower motor control module.
  34. Remove the blower motor. Refer to Blower Motor Replacement .
    35. Fig 18: HVAC Module Vacuum Harness & I/P Harness Vacuum Supply Line
    GM297262Courtesy of GENERAL MOTORS CORP.
  35. Disconnect the I/P harness vacuum supply line (1) from the HVAC module vacuum harness (2).
    36. Fig 19: Vacuum Electric Solenoid & Electrical Connector
    GM295337Courtesy of GENERAL MOTORS CORP.
  36. Disconnect the electrical connector from the vacuum electric solenoid.
    37. Fig 20: Windshield Defroster Duct & Screws
    GM95643Courtesy of GENERAL MOTORS CORP.
  37. Remove the windshield defroster duct retaining screws.
  38. Remove the windshield defroster duct.
    39. Fig 21: I/P Upper Support Beam, HVAC Module & Retaining Bolts
    GM175438Courtesy 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 I/P upper support beam.
  41. Carefully remove the HVAC module from the vehicle.
    42. Fig 22: HVAC Module Air Inlet, Drain & Plumbing Seals
    GM179036Courtesy of GENERAL MOTORS CORP.
  42. Remove and discard the HVAC module air inlet, drain and plumbing seals.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

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.