Roadmaster 1992

Removal & Installation

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NOTE
The heater/AC module must be removed to remove the vacuum tank and the heater shut off valve actuator.

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.


    NOTE
    If working near and/or around the SRS system and components, be sure to properly disable the SRS system. See disarming/arming the SRS system.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly discharge the air conditioning system.
  6.  
  7. Disconnect and plug the freon lines.
  8.  
  9. Drain the engine coolant. Be sure to properly dispose of used coolant.
  10.  
  11. Disconnect and cap the heater hoses.
  12.  
  13. Disconnect and cap the refrigerant lines at the evaporator ports. Discard the O-rings.
  14.  
  15. As necessary remove the instrument panel assembly to gain access to the component.

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    Fig. Heater/air conditioning ducts and related components-1991-1993



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    Fig. Instrument panel carrier assembly and related components-1991-1993



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    Fig. Instrument panel wiring harness and related components-1991-1993



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    Fig. Instrument panel upper trim pad and related components Roadmaster-1991-1993



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    Fig. Instrument panel lower trim pad and related components Roadmaster-1991-1993



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    Fig. Instrument panel lower trim pad and related components Caprice and Custom Cruiser-1991-1993



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    Fig. Instrument panel upper trim pad and related components Caprice and Custom Cruiser-1991-1993

  16.  
  17. Remove the floor air outlet assembly.
  18.  
  19. Disconnect the required electrical connectors, vacuum lines and cables from the component.
  20.  
  21. Remove the retaining bolts and nuts from the engine compartment, first.
  22.  
  23. Remove the component retaining nuts and bolts from inside the passenger-s compartment.
  24.  
  25. Slide the assembly rearward, tilting as required to ensure that the heater core tubes and evaporator core tubes are clear before removing the unit from the mounting studs.
  26.  
  27. Remove the heater/AC module from the vehicle.

    Click image to see an enlarged view

    Fig. Heater/AC module and related components-1991-1993

  28.  

To install:


NOTE
Be sure to use new fasteners, as required.


NOTE
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread sealer are identified. Do not use paints, lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners.

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to properly recharge the air conditioning system.
  4.  
  5. Be sure to fill the cooling system with the proper grade and type engine coolant.
  6.  
  7. Using the GM diagnostic scan tool or aftermarket equivalent reprogram the necessary systems and components. Be sure to follow the scan tool manufacturer-s directions.
  8.  

 
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