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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1738 (HEATING, VENTILATION, AND AIR CONDITIONING)REPAIR INSTRUCTIONSHVAC MODULE ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
WARNING: This page is about a different car, the 2009 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Thick Foam Packing On Heater Core Pipes
    GM819805Courtesy of GENERAL MOTORS CORP.
  1. Install the thick foam packing (1) on the heater core pipes.
  2. Install the thin foam packing (2) on the heater core pipes.
    3. Fig 2: View Of Thick Foam Packing On A/C Lines
    GM819804Courtesy of GENERAL MOTORS CORP.
  3. Install the thick foam packing (1) on the A/C lines.
  4. Install the thin foam packing (2) on the A/C lines.
    5. Fig 3: Locating Upper Left HVAC Module Mounting Nut
    GM756237Courtesy of GENERAL MOTORS CORP.
  5. Install the HVAC module into the vehicle.
    6. CAUTION: Refer to Fastener Caution .
  6. Install the upper left HVAC module mounting nut (1) and tighten to 9 N.m (80 lb in).
    7. Fig 4: Locating Lower Left HVAC Module Mounting Nut
    GM756232Courtesy of GENERAL MOTORS CORP.
  7. Install the lower left HVAC module mounting nut (1) and tighten to 9 N.m (80 lb in).
  8. Connect the drain tube to the bottom of the HVAC module.
    9. Fig 5: View Of Rubber Adhesive Patch & Drain Tube
    GM756222Courtesy of GENERAL MOTORS CORP.
  9. Connect the drain tube (2) to the floor.
  10. Connect the HVAC electrical connector.
  11. Install the air inlet assembly.
  12. Install the I/P carrier. Refer to Instrument Panel Carrier Replacement .
  13. Install new O-rings to the suction hose and liquid line. Refer to O-Ring Replacement .
  14. Connect the suction hose and liquid line to the evaporator core.
  15. Install the A/C quick connect fittings to the suction hose and liquid line. Refer to Air Conditioning Line/Tube Connector Removal/Replacement .
  16. Connect the heater inlet hose to the heater core. Refer to Heater Inlet Hose Replacement (LH2)  or Heater Inlet Hose Replacement (LY7) .
  17. Connect the heater outlet hose to the heater core. Refer to Heater Outlet Hose Replacement (LH2)  or Heater Outlet Hose Replacement (LY7) .
  18. Fill the coolant. Refer to Cooling System Draining and Filling (GE 47716) or Cooling System Draining and Filling (Static Fill) .
  19. Evacuate and recharge the AC system. Refer to Refrigerant Recovery and Recharging .
  20. Leak test the fittings of the component using J 39400-A  . See Special Tools .
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.