Corvette 1997-2005

Removal & Installation

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CAUTION
Before beginning this procedure, refer to the precautions at the beginning of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Recover the refrigerant.
  2.  
  3. Disable the air bag system.
    CAUTION
    Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the battery.
  8.  
  9. Remove the battery heat shield.
  10.  
  11. Drain the cooling system.
  12.  
  13. Remove the engine intake manifold.
  14.  
  15. Remove the nut retaining the heater pipe bracket to the dash panel.
  16.  
  17. Reposition the heater pipe bracket.
  18.  
  19. Remove the heater pipe to heater core retaining bolt.
  20.  
  21. Disconnect the heater pipe assembly from the heater core, allow any remaining coolant to drain, discard the seal washers and cap or plug the heater pipe assembly and the heater core to prevent contamination.
  22.  
  23. Remove the accumulator hose to evaporator retaining bolt.
    CAUTION
    Cap or tape the open accumulator hose, evaporator tube - rear and the evaporator immediately.

  24.  
  25. Disconnect the accumulator hose and the evaporator tube - rear from the evaporator, discard the O-ring seals and cap or tape the hose end, the tube end and the evaporator to prevent contamination.
  26.  
  27. Remove the evaporator and HVAC module drain tube from the HVAC module.
  28.  
  29. Remove the console.
  30.  
  31. Remove the I/P accessory trim plate.
  32.  
  33. Remove the glove box.
  34.  
  35. Remove the RH lower insulator panel.
  36.  
  37. Remove the driver knee bolster trim panel.
  38.  
  39. Remove the LH lower insulator panel.
  40.  
  41. Remove the I/P upper trim pad.
  42.  
  43. Remove the instrument panel cluster (IPC) to steering column bracket retaining screws.
  44.  
  45. Reposition the IPC to allow room for the HVAC module to be removed.
  46.  
  47. Remove the LH side window defogger outlet duct lower.
  48.  
  49. Disconnect the DRL sensor electrical connector from the LH side of the windshield defroster duct, if equipped.
  50.  
  51. Disconnect the electrical connector from the temperature valve electric actuator.
  52.  
  53. Remove the I/P center support bracket and the ignition switch housing bracket.
  54.  
  55. Remove the LH floor air outlet duct retaining screws.
  56.  
  57. Remove the floor air outlet duct.
  58.  
  59. Remove the LH floor air outlet duct rear. Rotate the duct ¼ turn clockwise to release.
  60.  
  61. Remove the RH side window defogger outlet duct lower.
  62.  
  63. Depress the defogger outlet duct lower retaining tabs and release the duct from the passenger SIR bracket.
  64.  
  65. Use a twisting motion to release the defogger outlet duct lower from the windshield defroster duct, then from the defogger outlet duct upper.
  66.  
  67. Remove the passenger SIR bracket and the passenger knee bolster bracket.
  68.  
  69. Remove the RH floor air outlet duct retaining screws.
  70.  
  71. Remove the floor air outlet duct.
  72.  
  73. Pull the front floor carpet away from the RH side of the driveline tunnel to access the carpet air outlet duct.
  74.  
  75. Use a rotating motion the release the carpet air outlet duct from the floor air outlet duct rear.
  76.  
  77. Remove the RH floor air outlet duct rear. Rotate the floor air outlet duct rear ¼ turn counterclockwise to release.
  78.  
  79. Disconnect the wiring harness electrical connector from the blower motor resistor.
  80.  
  81. Remove the blower motor w/impeller.
  82.  
  83. Disconnect the I/P harness vacuum source line from the HVAC module vacuum harness.
  84.  
  85. Remove the windshield defroster duct retaining screws.
  86.  
  87. Remove the windshield defroster duct.
  88.  
  89. Remove the HVAC module retaining and sealing nuts from the dash panel. Reposition the refrigerant lines slightly, if necessary.
  90.  
  91. Remove the HVAC module retaining screws from the I/P upper support beam.
  92.  
  93. Carefully remove the HVAC module from the vehicle.
  94.  
  95. Remove and discard the HVAC module air inlet, drain, and plumbing seals.
  96.  

To install:

  1. Install new air inlet, drain, and plumbing seals to the HVAC module.
  2.  
  3. Carefully install the HVAC module to the vehicle in the following SEQUENCE.
    NOTE
    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 dash panel and not the dashmat.

    1. Check the dashmat (1) for proper alignment to the dash panel; align if necessary. The opening in the dashmat for the HVAC module drain should be aligned so that the drain opening in the dash panel is approximately centered in the dash mat opening; allowing ample room for the module drain seal (2) to fully seat against the dash panel.
    2.  
    3. 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 dash panel.
    4.  
    5. INSERT the LH stud into the dash panel FIRST, then the module drain, then the RH stud.
    6.  
    7. Install the HVAC module LH retaining bolt to the I/P upper support beam module net locating hole (3).

      Click image to see an enlarged view

      Fig. HVAC module installation-1997-1999 models

    8.  

  4.  
  5. Install the HVAC module RH retaining bolt to the I/P upper support beam and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Install the HVAC module new retaining and sealing nuts to the dash panel and tighten to 89 inch lbs. (10 Nm). . Reposition the refrigerant lines slightly, if necessary.
  8.  
  9. Install and align the windshield defroster duct to the HVAC module opening and the I/P upper support beam.
  10.  
  11. Install the windshield defroster duct LH retaining screw (net locating hole).
  12.  
  13. Install the windshield defroster duct RH retaining screw.
  14.  
  15. Connect the I/P harness vacuum source line to the HVAC module vacuum harness.
  16.  
  17. Install the blower motor w/impeller.
  18.  
  19. Connect the wiring harness electrical connector to the blower motor resistor.
  20.  
  21. Position and align the RH floor air outlet duct rear to the HVAC module, then push firmly and evenly to secure the duct.
  22.  
  23. 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.
  24.  
  25. Position the front floor carpet to the RH side of the driveline tunnel.
  26.  
  27. Install the RH floor air outlet duct to the HVAC module.
  28.  
  29. Install the floor air outlet duct retaining screws.
  30.  
  31. Install the passenger SIR bracket and the passenger knee bolster bracket.
  32.  
  33. Install the RH side window defogger outlet duct lower.
  34.  
  35. Position and align the LH floor air outlet duct rear to the HVAC module, then push firmly and evenly to secure the duct.
  36.  
  37. Install the LH floor air outlet duct to the HVAC module.
  38.  
  39. Install the floor air outlet duct retaining screws.
  40.  
  41. Install the I/P center support bracket and the ignition switch housing bracket.
  42.  
  43. Connect the electrical connector to the temperature valve electric actuator.
  44.  
  45. Connect the DRL sensor electrical connector to the LH side of the windshield defroster duct, if equipped.
  46.  
  47. Install the LH side window defogger outlet duct lower.
  48.  
  49. Install the instrument panel cluster (IPC) into position.
  50.  
  51. Install the IPC to steering column bracket retaining screws.
  52.  
  53. Install the I/P upper trim pad.
  54.  
  55. Install the LH lower insulator panel.
  56.  
  57. Install the driver knee bolster trim panel.
  58.  
  59. Install the RH lower insulator panel.
  60.  
  61. Install the glove box.
  62.  
  63. Install the I/P accessory trim plate.
  64.  
  65. Install the console.
  66.  
  67. Install the evaporator and HVAC module drain tube to the module.
  68.  
  69. Check to be sure that the drain tube is fully seated to the HVAC module.
  70.  
  71. Remove the cap or tape from the accumulator hose, evaporator tube rear and the evaporator.
  72.  
  73. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the accumulator hose, evaporator tube rear and the evaporator.
  74.  
  75. Lightly coat the new O-ring seals with mineral base 525 viscosity refrigerant oil.
  76.  
  77. Carefully slide the new O-ring seals onto the accumulator hose and the evaporator tube rear until seated.
  78.  
  79. Install the accumulator hose and evaporator tube rear to the evaporator.
  80.  
  81. Install the accumulator hose to evaporator retaining bolt.
  82.  
  83. Remove the cap or plug from the heater pipe assembly and the heater core.
  84.  
  85. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the heater pipe assembly and the heater core.
  86.  
  87. Lightly coat the new seal washers with coolant.
  88.  
  89. Carefully slide the new seal washers onto the heater pipe assembly until seated.
  90.  
  91. Install the heater pipe assembly to the heater core.
  92.  
  93. Install the heater pipe assembly retaining bolt and tighten to 12 ft. lbs. (16 Nm).
  94.  
  95. Install the heater pipe bracket into position.
  96.  
  97. Install the heater pipe bracket retaining nut and tighten to 89 inch lbs. (10 Nm).
  98.  
  99. Install the engine intake manifold.
  100.  
  101. Install the battery heat shield.
  102.  
  103. Install the battery.
  104.  
  105. Connect the negative battery cable.
  106.  
  107. Enable the air bag system.
  108.  
  109. Refill the cooling system.
  110.  
  111. Inspect the heater core joint for leaks.
  112.  
  113. Evacuate and charge the refrigerant system.
  114.  
  115. Check the evaporator joint for leaks.
  116.  


CAUTION
Before beginning this procedure, refer to the precautions at the beginning of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Remove the center instrument panel accessory trim plate.
  2.  
  3. Remove the HVAC CON (HVAC controls) MiniFuse No. 27 from the IP electrical center, if equipped.
  4.  
  5. Remove the HVAC control module retaining screws.
  6.  
  7. Pull the HVAC control module out from the I/P center support bracket.
  8.  
  9. Disconnect the electrical connector from the HVAC control module.
  10.  
  11. Remove the HVAC control module from the vehicle.
  12.  

To install:

  1. Install the HVAC control module to the vehicle.
  2.  
  3. Connect the electrical connector to the HVAC control module.
  4.  
  5. Install the HVAC control module to the I/P center support bracket.
  6.  
  7. Install the HVAC control module retaining screws and tighten to 17 inch lbs. (1.9 Nm).
  8.  
  9. Install the center accessory trim plate.
  10.  
  11. Install the HVAC CON (HVAC controls) MiniFuse No. 27 to the IP electrical center, if equipped.
    NOTE
    Do not adjust any controls on the HVAC control module while the HVAC control module is self-calibrating. If interrupted, improper HVAC performance will result. The engine must be running for proper calibration to occur.

  12.  
  13. Start and allow the engine to run for a least one minute.
  14.  

 
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