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

Installation Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation 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. From the inside of the mode valve assembly, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit.
  2. Install the right front edge of the mode valve assembly under the recirculation housing.
  3. Install the mode valve assembly to the HVAC module assembly.
    4. Fig 1: Removing Rearward Retaining Screws
    GM1194938Courtesy of GENERAL MOTORS CORP.
  4. Install the two rearward retaining screws to the recirculation housing.
    5. Fig 2: Removing Mode Actuator
    GM1194936Courtesy of GENERAL MOTORS CORP.
  5. Install three new screws in the locations adjacent to the removed heat stakes in the mode valve assembly.
  6. Install the screws that were removed from the mode valve assembly to there original position.
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Tighten the recirculation housing, mode valve assembly and heat stake replacement screws.

    Tighten:  Tighten all the screws to 1.5 N.m (13 lb in).

  8. Position the mode actuator on to the HVAC module assembly.
  9. Install the mode valve actuator bolts.

    Tighten:  Tighten the bolts to 1.5 N.m (13 lb in).

  10. Install the I/P carrier to the vehicle. Align the I/P carrier to the HVAC module and the hinge pillars.
  11. Install the bolts to the right and the left I/P carrier.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    12. Fig 3: Removing HVAC Module Assembly Upper Support Bolts
    GM1197447Courtesy of GENERAL MOTORS CORP.
  12. Install the bolts to the HVAC module assembly upper support bracket.

    Tighten:  Tighten the bolts to 4 N.m (36 lb in).

    13. Fig 4: Removing HVAC Module Assembly Lower Support Bolts
    GM1273425Courtesy of GENERAL MOTORS CORP.
  13. Install the bolts to the HVAC module assembly lower support bracket (1).

    Tighten:  Tighten the bolts to 4 N.m (36 lb in).

  14. Install the bolts to the HVAC module assembly RH support bracket (2).

    Tighten:  Tighten the bolts to 4 N.m (36 lb in).

  15. Position the I/P wiring harness to the original position.
  16. Connect any disconnected ground wires.
  17. Install the BCM.
  18. Install the brake pedal brace bolts to the I/P carrier.
  19. Install the brake pedal and the brake pedal bolt.
  20. Install the booster push rod to the brake pedal.
  21. Seat the bottom junction block tabs and snap the top of the junction block to the passenger knee bolster.
  22. Install the junction block bolt.

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

  23. Install the I/P trim pad. Refer to Trim Pad Replacement - Instrument Panel (I/P) in Instrument Panel, Gages and Console.
  24. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
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.