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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 652 (HEATING, VENTILATION, AND AIR CONDITIONING)REPAIR INSTRUCTIONSHVAC MODULE ASSEMBLY REPLACEMENT (1ST DESIGN)REMOVAL 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 2008 Pontiac G5 and 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non HP2) .
  3. Drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill LE5, L61) or Cooling System Draining and Filling (Static Fill LNF) .
    4. Fig 1: View Of Heater Core Tubes And Outlet Hose
    GM872578Courtesy of GENERAL MOTORS CORP.
  4. Reposition the heater outlet hose clamp at the heater core using J 38185  .
  5. Remove the heater outlet hose from the heater core.
  6. Position the hose upright against the front of dash.
    7. Fig 2: View Of Heater Inlet Hose Clamp At Heater Core
    GM872572Courtesy of GENERAL MOTORS CORP.
  7. Reposition the heater inlet hose clamp at the heater core using J 38185  .
  8. Remove the heater inlet hose from the heater core.
  9. Position the hose upright against the front of dash.
    10. Fig 3: View Of Evaporator Tube & Compressor Suction Hose At TXV
    GM872539Courtesy of GENERAL MOTORS CORP.
  10. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
  11. Remove and discard the seal washers.
    12. Fig 4: View Of HVAC Module Front Dash Nuts
    GM872581Courtesy of GENERAL MOTORS CORP.
  12. Remove the HVAC module nuts from the front of dash.
    13. Fig 5: View Of Blower Motor Electrical Connector
    GM872586Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the blower motor connector.
    14. Fig 6: View Of Blower Motor Resistor Electrical Connector
    GM872583Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the blower motor resistor electrical connector.
  15. Remove the instrument panel (I/P) tie bar. Refer to Instrument Panel Tie Bar Replacement .
    16. Fig 7: View Of Center Floor Outlet Duct
    GM873732Courtesy of GENERAL MOTORS CORP.
  16. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts.
  17. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage the duct from the HVAC module.
    18. Fig 8: View Of Recirculation Actuator Electrical Connector
    GM873741Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the recirculation actuator electrical connector.
  19. 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.