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HVAC Module: Installation

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.
CAUTION: A NEW cabin air filter housing seal must be used whenever the housing is removed to prevent water from leaking into HVAC module.
CAUTION: On Wagons, rear washer supply hose is routed through drivers side A-pillar. Use care not to pinch or damage hose.
  1. Install HVAC module into vehicle and hand start bolts. See Figure .
  2. Using a small flat-blade screwdriver, remove cabin air filter housing seal. See Figure . Install a NEW cabin air filter housing seal. Install cabin air filter housing and housing screws. Tighten to specification.
  3. Reposition wiper module and install wiper module bolts. See Figure . Tighten to specification. See TORQUE SPECIFICATIONS  .
  4. Tighten HVAC module mounting bolts. See TORQUE SPECIFICATIONS  . Install evaporator drain tube and bolt. See Figure . Tighten to specification.
  5. Install cabin air filter paying special attention to the air flow direction indicator printed on side of the filter. Rotate locking tabs on cabin air filter housing inward to secure cabin air filter in place. See Figure .
  6. Install cowl screen and fasteners. See Figure . Make sure that cabin air filter access door is closed. Install weatherstrip at rear of engine compartment. See Figure .
  7. Install wiper arm assemblies. See Figure . Tighten wiper arm retaining nuts to specification. SeeTORQUE SPECIFICATIONS  .
  8. Install I/P beam into vehicle. Using a large screwdriver, pry steering column braces apart to clear I/P beam studs and slide I/P beam forward to locate studs into holes. See Figure . DO NOT install steering column brace nuts at this time. Install wiring harness to I/P beam. See Figure .
  9. Open drivers side door completely and install protective covering on door inner hinge area to prevent damage to paint. Install Tool Flange into A-pillar beam bolt holes. See Figure . Tool Flange should fit tight to the A-pillar surface when completely installed. This tool is needed to prevent accidental dropping of studs inside A-pillar. Using appropriate socket, install both inner beam studs. See Figure . Tighten inner beam studs to specification. See TORQUE SPECIFICATIONS  .
  10. Remove Flange Tool. Install upper and lower outer beam bolts. See Figure . Tighten to specification. See TORQUE SPECIFICATIONS  . Install black plastic bolt caps. See Figure . Repeat beam stud/bolt installation procedure on passenger side.
  11. Install I/P beam to steering column brace nuts and tighten to specification. See TORQUE SPECIFICATIONS  .
  12. Install "H" brace and "H" brace fasteners. Connect I/P-to-HVAC harness connector and install connector to I/P beam. See Figure . Route temperature door cable around outside of right "H" brace.
  13. For vehicles equipped with advanced audio system, connect amplifier wire harness connectors and slide amplifier onto clutch pedal bracket. Position amplifier to I/P beam and install fasteners. Tighten to specification. See TORQUE SPECIFICATIONS  .
    14. WARNING: Behind nut is a plastic locator for the steering column. This piece will center steering column in front of driver in event of an accident.
  14. Install upper and lower steering column mount bolts and upper steering column mount nut along with locator. See Figure . Tighten steering column attachment fasteners to specification. See TORQUE SPECIFICATIONS  .
    15. WARNING: Use LOCTITE 242(R) Threadlocker, or equivalent, on the threads of the pinch bolt.
  15. Connect intermediate shaft and install pinch bolt. Tighten to specification. See TORQUE SPECIFICATIONS  .
  16. Install I/P assembly. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
  17. Install the heater inlet hose, closest to drivers side.
    • Hold hose by black quick connect collar and slide hose onto heater core pipe until quick connect collar engages over bead on heater core pipe.
    • Ensure that a Green band is visible in quick connect collar.
    • Pull on hose to ensure it is properly seated.
    See Figure .
    18. NOTE: Earlier vehicles used a bolt instead of a stud/nut.
  18. Remove cap or tape from TXV and suction/liquid line assembly block. Thoroughly clean "O" ring surfaces. Lubricate and install NEW "O" rings on suction/liquid line assembly block. Install suction/liquid line assembly block to TXV. See Figure . Install suction/liquid line assembly to TXV nut and tighten to specification. See TORQUE SPECIFICATIONS  .
  19. Rinse off any coolant that was spilled in engine compartment and reconnect battery cable. Fill cooling system.
  20. Evacuate and recharge A/C system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Ensure A/C system is operating properly. See A/C SYSTEM PERFORMANCE  under PERFORMANCE TESTS.
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