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HVAC Module: Assembly

WARNING: This page is about a different car, the 2002 Saturn LW300, 2002 Saturn LW200, 2002 Saturn L300, 2002 Saturn L200, and 2002 Saturn L100. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install temperature, heater, defroster, and vent doors into case. See Figure . Install right side of case, carefully lining up door shafts with case openings. Verify that each door can be easily rotated through entire range of motion. Install case screws and clips. Tighten to specification. See TORQUE SPECIFICATIONS  .
  2. Install evaporator into bottom of case, install module lower case, install and tighten screws. See Figure .
  3. Install heater core into case. See Figure . Install NEW bushings and "O" rings onto heater core pipes. Install heater pipes into case and then into heater core. Shorter pipe is upper. Heater pipe clamps will only go on one way. Lower clamp hinge fits into tab of heater core retaining strap. See Figure . Install heater core retaining strap and tighten to specification. See TORQUE SPECIFICATIONS  .
  4. Install TXV/Heater pipe seal. Install TXV. See THERMAL EXPANSION VALVE  .
  5. Install recirculation doors. Install recirculation door rod to small door and with both doors held firmly closed, snap rod into retainer clip and close clip. See Figure . Recirculation door shaft has 2 flats that must be aligned to recirculation motor. To install recirculation motor, align with door shaft and slide into position. Install recirculation motor bracket to module screws. See Figure . Tighten to specification. See TORQUE SPECIFICATIONS  .
  6. Install vent and heater door sub-levers. These sub-levers are identical and should have slotted end inward. Install defrost door sub-lever. See Figure .
  7. Install vent and heater primary levers. See Figure . Tighten to specification. See TORQUE SPECIFICATIONS  .
  8. Install mode cam and rotate to verify proper installation. See Figure . Install mode motor and mode motor screws. See Figure . Tighten to specification. See TORQUE SPECIFICATIONS  .
  9. Install blower motor resistor card. Vehicles equipped with automatic climate control, install blower motor control module. See Figure . Install blower motor resistor card screw and tighten to specification. See TORQUE SPECIFICATIONS  .
  10. Install temperature door cable eyelet over temperature door lever, but do not install housing into retaining clip at this time. Attach electrical harness to back of HVAC module. Connect actuators, blower motor resistor card, and route to blower motor. Vehicles equipped with automatic climate control, attach electrical harness to back of module. Connect actuators, blower motor control module and route to blower motor. Push blower motor harness grommet through hole then pull back to seat. Install harness to case screw at mode motor.
  11. Install blower motor assembly into module housing. Blower motor assembly rib must fit into channel in housing. See Figure . Connect blower motor electrical connector.
  12. Install connector duct to HVAC module and install screw. See Figure . Tighten to specification. See TORQUE SPECIFICATIONS  . Install lower insulator into forward edge of case then stretch to hook on barbs. See Figure .
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