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HOMESERVICE MANUALSCHEVROLET2011TAHOE BASE, 5.3 0, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 490 (HEATING, VENTILATION AND AIR CONDITIONING)REPAIR INSTRUCTIONSHVAC MODULE ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2011 Chevrolet Tahoe Base, 5.3 0, 4WD

Installation Procedure

2011 Chevrolet Tahoe Base, 5.3 0, 4WDSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Installing Air Inlet Drain And Plumbing Seals To HVAC Module
    G01418640Courtesy of GENERAL MOTORS CORP.
  1. Install new air inlet, drain and plumbing seals to the HVAC module.
    2. Fig 2: Installing HVAC Module To Vehicle
    G01418641Courtesy of GENERAL MOTORS CORP.
  2. Carefully install the HVAC module to the vehicle in the following SEQUENCE.

    Important:  Ensure that the cut-outs on the dashmat are properly aligned so that the air inlet, drain, and plumbing seals are seated directly against the cowl and not the dashmat.

    1. 2.1. Inspect the dashmat (1) for proper alignment to the cowl. Align if necessary.

      The opening in the dashmat for the HVAC module drain should be aligned so that the drain opening in the cowl is approximately centered in the dash mat opening; allowing ample room for the module drain seal (2) to fully seat against the cowl.

    2. 2.2. ALIGN the heater core joint fitting, the condenser joint fitting, the HVAC module drain and the HVAC module studs to the corresponding openings on the cowl.
    3. 2.3. INSERT the LH stud into the cowl FIRST, then the module drain, then the RH stud.
    4. 2.4. Install the HVAC module LH retaining bolt to the IP upper support beam module net locating hole (3).
      NOTE: Refer to FASTENER NOTICE .
    5. 2.5. Install the HVAC module RH retaining bolt to the IP upper support beam.

      Tighten 

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

      Important:  To prevent possible water leaks or wind/road noise from entering the vehicle passenger compartment, DO NOT reuse the old HVAC module retaining and sealing nuts.

    6. 2.6. Install the HVAC module new retaining and sealing nuts.
    7. 2.7. Tighten the HVAC module retaining and sealing nuts.

    Tighten 

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

  3. Install and align the windshield defroster duct to the HVAC module opening and the IP upper support beam.
  4. Install the windshield defroster duct LH retaining screw (net locating hole).
  5. Install the windshield defroster duct RH retaining screw.

    Tighten 

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

    Fig 3: Installing Windshield Defroster Duct
    G01418642Courtesy of GENERAL MOTORS CORP.
  6. Connect the electrical connector to the vacuum electric solenoid.
    Fig 4: Connecting Electrical Connector To Vacuum Electric Solenoid
    G01418643Courtesy of GENERAL MOTORS CORP.
  7. Connect the IP harness vacuum supply line (1) to the HVAC module vacuum harness (2).
    Fig 5: Connecting IP Harness Vacuum Supply Line To HVAC Module Vacuum Harness
    G01418644Courtesy of GENERAL MOTORS CORP.
  8. Install the blower motor. Refer to BLOWER MOTOR REPLACEMENT  .
  9. Connect the electrical connector to the blower motor control module.
    Fig 6: Connecting Electrical Connector To Blower Motor Control Module
    G01418645Courtesy of GENERAL MOTORS CORP.
  10. Position and align the RH floor air outlet duct-rear to the HVAC module, then push firmly and evenly to secure the duct.
    Fig 7: Installing RH Floor Air Outlet Duct-Rear To HVAC Module
    G01418646Courtesy of GENERAL MOTORS CORP.
  11. Secure the carpet air outlet duct to the RH floor air outlet duct - rear.

    Use a rotating motion to secure the carpet air outlet duct to the floor air outlet duct - rear.

  12. Position the front floor carpet to the RH side of the driveline tunnel.
    Fig 8: Installing Carpet Air Outlet Duct To RH Floor Air Outlet Duct - Rear
    G01418647Courtesy of GENERAL MOTORS CORP.
  13. Install the RH floor air outlet duct to the HVAC module.
  14. Install the RH floor air outlet duct retaining screws.

    Tighten 

    Tighten the screws to 1.6 N.m (14 lb in).

    Fig 9: Installing RH Floor Air Outlet Duct To HVAC module
    G01418648Courtesy of GENERAL MOTORS CORP.
  15. Connect the electrical connector to the RH temperature actuator.
    16. Fig 10: Connecting Electrical Connector To RH Temperature Actuator
    G01418649Courtesy of GENERAL MOTORS CORP.
  16. Connect the sunload sensor electrical connector.
  17. Install the passenger SIR bracket and the passenger knee bolster bracket. Refer to BRACKET REPLACEMENT - KNEE BOLSTER (DRIVER) or BRACKET REPLACEMENT - KNEE BOLSTER (DRIVER OUTER) or BRACKET REPLACEMENT - KNEE BOLSTER (PASSENGER) in Instrument Panel, Gages and Console.
  18. Install the RH side window defogger outlet duct - lower.
    1. 18.1 Use a twisting motion to secure the defogger outlet duct - lower to the defogger outlet duct - upper, then to the windshield defroster duct.
    2. 18.2 Install the defogger outlet duct - lower retaining tabs to the passenger SIR bracket.
    Fig 11: Installing RH Side Window Defogger Outlet Duct - Lower
    G01418650Courtesy of GENERAL MOTORS CORP.
  19. Position and align the LH floor air outlet duct - rear to the HVAC module, then push firmly and evenly to secure the duct.
    Fig 12: Aligning LH Floor Air Outlet Duct - Rear To HVAC Module
    G01418651Courtesy of GENERAL MOTORS CORP.
  20. Install the LH floor air outlet duct to the HVAC module.
  21. Install the LH floor air outlet duct retaining screws.

    Tighten 

    Tighten the screws to 1.6 N.m (14 lb in).

  22. Install the IP center support bracket and the ignition switch housing bracket. Refer to BRACKET REPLACEMENT - INSTRUMENT PANEL (I/P) CENTER SUPPORT in Instrument Panel, Gages and Console.
    Fig 13: Installing LH Floor Air Outlet Duct To HVAC Module
    G01418652Courtesy of GENERAL MOTORS CORP.
  23. Connect the electrical connector to the LH temperature actuator.
    24. Fig 14: Connecting Electrical Connector To LH Temperature Actuator
    G01418653Courtesy of GENERAL MOTORS CORP.
  24. Connect the DRL sensor electrical connector, if equipped.
    25. Fig 15: Installing Inside Air Temperature Sensor Aspirator Duct Muffler
    G01418654Courtesy of GENERAL MOTORS CORP.
  25. Install the inside air temperature sensor aspirator duct muffler.

    Use a twisting motion to secure the duct muffler.

    26. Fig 16: Installing Inside Air Temperature Sensor Aspirator Duct
    G01418655Courtesy of GENERAL MOTORS CORP.
  26. Install the inside air temperature sensor aspirator duct.
    1. 26.1 Use a twisting motion to secure the duct to the duct muffler.
    2. 26.2 Install the duct retaining tab to the ignition switch housing bracket.
    27. Fig 17: Installing LH Side Window Defogger Outlet Duct - Lower
    G01418656Courtesy of GENERAL MOTORS CORP.
  27. Install the LH side window defogger outlet duct - lower.
    1. 27.1 Use a twisting motion to secure the defogger outlet duct - lower to the defogger outlet duct - upper, then to the windshield defroster duct.
    2. 27.2 Install the push-in retainer.
  28. Install the IP upper trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) UPPER in Instrument Panel, Gages and Console.
  29. Install the HVAC module drain tube to the module.
    • Ensure that the drain tube is fully seated to the HVAC module.
    • Align the drain tube to contact the cowl as shown (1).
    Fig 18: Aligning Drain Tube To Contacting cowl
    G01418657Courtesy of GENERAL MOTORS CORP.
  30. Remove the cap or tape from the accumulator hose, evaporator tube - rear and the evaporator.
  31. Install a new O-ring. Refer to O-RING REPLACEMENT  .
    32. Fig 19: Installing Accumulator Hose And Evaporator Tube - Rear To Evaporator
    G01418658Courtesy of GENERAL MOTORS CORP.
  32. Install the accumulator hose and evaporator tube - rear to the evaporator.
  33. Install the accumulator hose to evaporator retaining bolt.

    Tighten 

    Tighten the bolt to 16 N.m (12 lb ft).

  34. Remove the cap or plug from the heater pipe assembly and the heater core.
  35. Install new sealing washers. Refer to SEALING WASHER REPLACEMENT  .
    36. Fig 20: Installing Heater Pipe Assembly
    G01418659Courtesy of GENERAL MOTORS CORP.
  36. Connect the heater pipe assembly to the heater core.
  37. Install the heater pipe assembly retaining bolt.

    Tighten 

    Tighten the bolt to 16 N.m (12 lb ft).

    38. Fig 21: Installing RH Air Injection Pipe
    G01418660Courtesy of GENERAL MOTORS CORP.
  38. Install the RH air injection pipe.
  39. Install the RH air injection pipe to RH cylinder head bolts.

    Tighten 

    Tighten the bolts to 20 N.m (15 lb ft).

  40. Install the RH air injection check valve to LH cylinder head bolt.

    Tighten 

    Tighten the bolt to 20 N.m (15 lb ft).

  41. Connect the hose and hose clamp to the RH air injection check valve.
    42. Fig 22: Installing Heater Pipe Bracket
    G01418661Courtesy of GENERAL MOTORS CORP.
  42. Install the heater pipe bracket into position.
  43. Install the heater pipe bracket retaining nut.

    Tighten 

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

  44. Install the intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT in Engine Mechanical 5.7-L.
  45. Install the battery heat shield. Refer to BATTERY HEAT SHIELD REPLACEMENT in Engine Electrical.
  46. Evacuate and recharge the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING  .
  47. Leak test the fittings of the component using J 39400-A  .
RENDER: 1.0x

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  • • You are missing required tools, torque specs, or safe lifting equipment.
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