LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2002 >> Windstar Base >> Repair and Diagnosis >> External Pages >> Different car >> Section 15 (Manual A/C-Heater Systems) >> Removal & Installation >> HVAC Module >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

HVAC Module: Installation

WARNING: This page is about a different car, the 2002 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Make sure seals on HVAC module are flush and even as the meet their mating surfaces. This will reduce the chance of leaks and insure proper fit.
  1. Check front of dash seal for proper alignment.
  2. Check seal mating surfaces to insure there are no obstructions.
    3. NOTE: Make sure center "molded in case" HVAC to cross car beam bracket is forward of cross car beam down flange.
  3. Loosely hang the HVAC module from cross car beam. See Fig 7 .
    4. CAUTION: NEW front of dash seal nuts must be used to prevent leaks.
  4. Install front of dash to HVAC module seal nuts, draw module to front of dash evenly with nuts and tighten. Tighten the nuts to specification. See TORQUE SPECIFICATIONS  .
  5. Push up on HVAC module at blower motor area while tightening right side HVAC module to cross car beam fasteners (to seat screen assembly/fresh air seal). Tighten the fasteners to specification.
  6. Install the left HVAC module to cross car beam stamped metal L-type bracket to HVAC module and cross car beam and tighten remaining module attachment fasteners. See Fig 6 . Tighten the fasteners to specification.
  7. Connect I/P wire harness clips to HVAC module.
  8. Install defroster duct to HVAC module nuts and defroster duct. See Fig 5 . Tighten the nuts to specification. See TORQUE SPECIFICATIONS  .
  9. Connect I/P harness to blower motor connector. See Figure .
  10. Connect I/P harness to blower motor resistor connector.
  11. Connect I/P harness to HVAC module connector.
  12. Install auxiliary duct assembly. See Fig 4 .
  13. Install front rear duct by sliding forward on heater duct then down and rearward over rear duct. See Fig 3 .
  14. Install the shift control bracket. See Figure .
  15. Install the I/P retainer.
  16. Install heater inlet hose to heater core inlet. See Figure .
  17. Position the clamp at 9 o'clock using hose clamp pliers.
  18. Install heater outlet hose to heater core outlet. See Figure .
  19. Position the clamp at 9 o'clock position using hose clamp pliers.
  20. Insure mating surfaces are clean and free of debris, and install a NEW seal washer to the liquid line.
  21. Install the liquid line and nut to the TXV. Tighten the nut to specification. See TORQUE SPECIFICATIONS  .
  22. Insure mating surfaces are clean and free of debris, and install a NEW seal washer to the suction hose.
  23. Install the suction hose and nut to the TXV. Install the TXV temperature sensor connector. See Figure . Tighten the nut to specification.
  24. Fill the coolant.
  25. Evacuate, charge and leak test A/C system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
Fig 1: Removing & Installing Liquid Line At TXV
G00228367Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing Thermistor Connector
G00209851Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing Front Rear Duct
G00217114Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing Auxiliary Duct Assembly
G00217115Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing Defroster Duct
G00217117Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing & Installing "L" Bracket
G00228368Courtesy of GENERAL MOTORS CORP.
Fig 7: Removing & Installing HVAC Module
G00228369Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals