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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 143 (HEATING, VENTILATION AND AIR CONDITIONING)REPAIR INSTRUCTIONSHVAC MODULE ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Removal Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Removal Procedure
WARNING: This page is about a different car, the 2005 Buick LaCrosse and 2005 Buick Allure. However, it is still accessible from the selected car via links, so may be relevant.
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L or Air Cleaner Assembly Replacement in Engine Controls - 3.6L.
  4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
  5. Drain the cooling system. Refer to Draining and Filling Cooling System (LY7) or Draining and Filling Cooling System (L26) in Engine Cooling.
  6. Remove the instrument panel (I/P) trim pad. Refer to Trim Pad Replacement - Instrument Panel (I/P) in Instrument Panel, Gages, and Console.
  7. Remove the bolt from the accessory wiring junction block.
  8. Disengage the junction block tabs from the passenger knee bolster. Remove the junction block from the knee bolster.
  9. Remove the brake pedal nut and bolt.
  10. Remove the brake pedal brace bolts from the I/P carrier cross car beam.
  11. Disconnect any ground wires, as necessary.
  12. Reposition the I/P wiring harness out of the way.
    13. Fig 1: Removing HVAC Module Assembly Lower Support Bolts
    GM1273425Courtesy of GENERAL MOTORS CORP.
  13. Remove the bracket bolt from the HVAC module assembly right support (2).
  14. Remove the bracket bolts from the HVAC module assembly lower support (1).
    15. Fig 2: Removing HVAC Module Assembly Upper Support Bolts
    GM1197447Courtesy of GENERAL MOTORS CORP.
  15. Remove the bracket bolts from the HVAC module assembly upper support.
  16. Remove the right and the left I/P carrier bolts.
  17. Remove the I/P carrier.
    18. Fig 3: Evaporator Tube On The Left Fender Rail
    GM1117979Courtesy of GENERAL MOTORS CORP.
  18. Remove the nut that secures the evaporator tube to the thermostatic expansion valve (TXV).
  19. Disconnect the evaporator tube from the TXV.
  20. Remove the seal washers and discard.
    21. Fig 4: View Of Heater Hose To Heater Core
    GM1204093Courtesy of GENERAL MOTORS CORP.
  21. UseJ 38185  in order to position aside the inlet heater hose clamp at the heater core.
  22. Use J 38185  in order to position aside the outlet heater hose clamp at the heater core.
  23. Disconnect the inlet heater hose from the heater core.
  24. Disconnect the outlet heater hose from the heater core.
  25. Disconnect the electrical connectors from the HVAC module assembly.
    26. Fig 5: Removing Evaporator Drain Elbow
    GM1284759Courtesy of GENERAL MOTORS CORP.
  26. Remove the evaporator drain elbow.
    27. Fig 6: View Of HVAC Module Assembly
    GM507700Courtesy of GENERAL MOTORS CORP.
  27. Remove the nuts which secure the HVAC module assembly to the dash.
  28. Remove the HVAC module assembly.
    29. Fig 7: Removing HVAC Module Assembly Seals
    GM1263072Courtesy of GENERAL MOTORS CORP.
  29. Remove all of the seals (1, 2, 3) from the outer HVAC module assembly.
RENDER: 1.0x

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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.