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HVAC Module: Disassembly

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. Remove temperature cable from module retaining clip using first 2 fingers to pull outward on the cable while using the thumb to spread retaining clip. Remove cable from temperature door lever by squeezing the end of the pin and pulling cable eyelet outward. See Figure .
  2. Remove blower motor housing screws, release both tabs, and remove housing. Lift blower motor upward and disconnect blower motor electrical connector by squeezing bottom of connector while pulling downward. See Figure .
  3. Remove HVAC module electrical harness connectors from mode motor, blower resistor card, and recirculation motor. Pull blower motor harness grommet out of case. See Fig 1 .
  4. Remove HVAC harness retaining screw at mode motor on case and remove harness connector by sliding harness to the left.
  5. Remove duct screw and pull connector duct downward to remove. See Fig 2 .
  6. Remove mode motor screws and remove mode motor. See Fig 3 . Remove mode cam. See Fig 4 . Remove primary lever screws and remove primary levers. See Fig 5 . Pry sub-levers off with a flat-blade screwdriver. See Fig 6 .
  7. Remove recirculation motor screws and remove recirculation motor. See Fig 7 .
  8. Remove blower motor resistor card screws and remove blower motor resistor card. Vehicles equipped with automatic climate control, remove blower motor control module. See Figure .
  9. Remove lower insulator by stretching past 2 hooks on bottom case and pulling forward. See Fig 8 .
  10. Open heater core pipe connector collars and remove. Clamps may need to be rotated to gain access to retaining tab. Pull heater core pipes out of the heater core and through the HVAC module case to remove. See Figure . Remove heater core retainer and slide heater core out of HVAC module. See Figure .
  11. Turn module upside down and remove lower case screws and remove lower case. See Fig 9 . Remove evaporator, TXV, and seal by lifting straight up. Remove TXV and seal from evaporator.
  12. Turn module right side up and use a razor blade to cut defroster/vent seal and blower motor opening seal at center line. See Fig 10 .
  13. Release recirculation door connecting rod from retainer. See Fig 11 . Remove rod from small door lever and remove. Remove large and small recirculation doors.
  14. Remove case half retainer clips and screws. There are 2 clips and 9 screws. There are 2 screws that are located in deep cavities. There is one screw located at the center of the case. See Fig 12 .
  15. With case laying on the side, lift right side straight up to split module. See Fig 13 .
  16. Remove mode and temperature doors. See Fig 14 .
Fig 1: Identifying HVAC Module Components
G00223018Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing & Installing Connector Duct
G00223020Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing & Installing Mode Motor
G00223021Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing & Installing Mode Cam
G00223022Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing & Installing Primary Levers
G00223023Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing & Installing Sub-Levers
G00223024Courtesy of GENERAL MOTORS CORP.
Fig 7: Removing & Installing Recirculation Motor
G00223025Courtesy of GENERAL MOTORS CORP.
Fig 8: Removing & Installing Lower Insulator
G00223026Courtesy of GENERAL MOTORS CORP.
Fig 9: Removing & Installing Lower HVAC Case
G00223027Courtesy of GENERAL MOTORS CORP.
Fig 10: Cutting HVAC Case Seals
G00223028Courtesy of GENERAL MOTORS CORP.
Fig 11: Removing & Installing Recirculation Door Connecting Rod
G00223029Courtesy of GENERAL MOTORS CORP.
Fig 12: Identifying HVAC Case Halves Screws & Clips
G00223030Courtesy of GENERAL MOTORS CORP.
Fig 13: Separating HVAC Case Halves
G00223031Courtesy of GENERAL MOTORS CORP.
Fig 14: Removing & Installing Temperature & Mode Doors
G00223032Courtesy of GENERAL MOTORS CORP.
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