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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 472 (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 2006 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disable the frontal and curtain air bags. Refer to the following procedures:
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  3. Drain the engine coolant. Refer to Draining and Filling Cooling System (GE 47716 Fill) or Draining and Filling Cooling System (Static Fill) .
    4. Fig 1: Evaporator Outlet Hose, Liquid Line Retainer Plate, Nut & TXV
    GM1506428Courtesy of GENERAL MOTORS CORP.
  4. Remove the evaporator outlet hose and liquid line nut from the thermal expansion valve (TXV).
  5. Remove the evaporator outlet hose from the TXV.
  6. Remove and discard the sealing washer from the evaporator outlet hose. Refer to Sealing Washer Replacement .
    7. Fig 2: Evaporator Outlet Hose, Liquid Line & TXV
    GM1506429Courtesy of GENERAL MOTORS CORP.
  7. Remove the evaporator outlet hose and liquid line from the TXV.
  8. Remove and discard the sealing washer from the liquid line. Refer to Sealing Washer Replacement .
  9. Install a protective caps to the evaporator outlet hose and the liquid line to prevent contamination and desiccant saturation.
  10. Disconnect the TXV low temperature sensor connector from the engine harness.
    11. Fig 3: Heater Outlet, Hose Clamp & Heater Core
    GM931798Courtesy of GENERAL MOTORS CORP.
  11. Reposition the heater outlet hose clamp at the heater core using SA9111E  . See Special Tools .
  12. Remove the heater outlet hose from the heater core.
    13. Fig 4: Heater Inlet, Hose Clamp & Heater Core
    GM931806Courtesy of GENERAL MOTORS CORP.
  13. Reposition the heater inlet hose clamp at the heater core using SA9111E  . See Special Tools .
  14. Remove the heater inlet hose at the heater core.
  15. Plug the heater core and the evaporator core with clean towels to prevent spillage when the HVAC module is removed.
    16. Fig 5: HVAC Module Seal & Nuts
    GM931912Courtesy of GENERAL MOTORS CORP.
  16. Remove the HVAC module seal nuts from the front of dash.
  17. Remove the instrument panel (I/P) retainer. Refer to Instrument Panel (I/P) Retainer Replacement .
  18. Remove the shift control bracket. Refer to Shift Control Replacement for the 5AT transmission or Floor Shift Control Replacement for the 4T45-E transaxle or Shift Control Replacement for the Getrag 5 speed transmission.
    19. Fig 6: Center Floor Air Outlet Duct
    GM933579Courtesy of GENERAL MOTORS CORP.
  19. Remove the center floor air outlet duct by sliding the duct forward then up at the rear.
    20. Fig 7: Center I/P Duct
    GM1644812Courtesy of GENERAL MOTORS CORP.
  20. Remove the center I/P air outlet duct retainers from the cross car beam.
  21. Remove the center I/P air outlet duct from the cross car beam.
    22. Fig 8: Blower Motor Electrical Connector & I/P Wire Harness
    GM932498Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the blower motor electrical connector from the I/P wire harness.
  23. Disconnect the blower motor resistor electrical connector from the I/P wire harness.
  24. Disconnect the HVAC module electrical connector from the I/P wire harness.
    25. Fig 9: Defroster Duct
    GM1644813Courtesy of GENERAL MOTORS CORP.
  25. Remove the defroster duct retainer from the cross car beam.
  26. Remove the defroster duct nuts from the HVAC module.
  27. Remove the defroster duct from the HVAC module.
  28. Disconnect the I/P wire harness clips from the HVAC module.
    29. Fig 10: Metal Bracket & Nut
    GM933704Courtesy of GENERAL MOTORS CORP.
  29. Remove the metal bracket nut from the cross car beam.
  30. Remove the metal bracket nuts from the HVAC module.
  31. Remove the metal bracket from the HVAC module.
    32. Fig 11: HVAC Module, Bolts & Cross Car Beam
    GM933686Courtesy of GENERAL MOTORS CORP.
  32. Remove the HVAC module bolts from the right side of the cross car beam.
  33. Remove the HVAC module nut from the center of the cross car beam.
  34. Remove HVAC module bolt from the left side of the cross car beam.
  35. Remove the HVAC module from the vehicle.
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.