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Heater Systems: Removal & Installation Chevrolet Silverado 2500

Heater 15 illustrations ~1431 words

REMOVAL & INSTALLATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
WARNINGAvoid contact with moving parts and hot surfaces while working around a running engine in order to prevent physical injury.
CAUTIONWhen battery is disconnected, radio may go into anti-theft protection mode. Obtain radio anti-theft protection code from owner prior to servicing vehicle.

Note. Any information not covered in this article may be found in AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON article in MANUAL A/C-HEATER SYSTEMS.

Note. Vehicles without air conditioning do not have electric door actuators. The manufacturer does not separate "heater only" information from air conditioned vehicle information.

  1. If equipped, remove the sound insulator panel. Remove the blower motor insulating cover screws. Disconnect the electrical connector from the blower motor. Remove the blower motor insulating cover. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the HVAC module. (Scheme 5) Remove the blower motor. (Scheme 6)
  2. Install the blower motor. (Scheme 6) Install the blower motor to the HVAC module. Turn the blower assembly clockwise until the retaining tab locks into place. Install the blower motor insulating cover. Connect the electrical connector to the blower motor Install the blower motor insulating cover screws. Tighten the screws to specification. See «TORQUE SPECIFICATIONS»(ref-152575-S17008195592003021200000). If equipped, install the sound insulator panel.

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6
  1. If equipped, remove the I/P sound insulator. Disconnect the electrical connection from the blower motor. Disconnect the electrical connection from the blower motor resistor. Remove the blower motor resistor retaining screws. Remove the blower motor resistor. (Scheme 7)
  2. Install the blower motor resistor. (Scheme 7) Install the blower motor resistor retaining screws. Tighten the screws to specification. See «TORQUE SPECIFICATIONS»(ref-152575-S17008195592003021200000). Connect the electrical connection to the blower motor resistor. Connect the electrical connection to the blower motor. If equipped, install the I/P sound insulator.

Scheme 7

Scheme 7
Scheme 7

Removal

  1. Remove the HVAC module. See «HVAC MODULE»(ref-152575-S00067383442003021200000). Remove the HVAC module screws. Separate the HVAC module. (Scheme 8) Remove the mode actuator screws.
  2. Remove the mode actuator. Remove the mode actuator cam assembly. (Scheme 8) Remove the defroster door lever. Remove the defroster door.

Installation

  1. Install the defroster door. Install the defroster door lever. (Scheme 8) Install the mode actuator cam assembly.
  2. Install the mode actuator. Install the mode actuator screws. Tighten the screws to specification. See «TORQUE SPECIFICATIONS»(ref-152575-S17008195592003021200000).
  3. Install the HVAC module halves. (Scheme 8) Install the screws to the HVAC module. Tighten the screws to specification. See «TORQUE SPECIFICATIONS»(ref-152575-S17008195592003021200000). Install the HVAC module.

Scheme 8

Scheme 8
Scheme 8

Remove the HVAC module. See HVAC MODULE. Remove the heater core cover screws. (Scheme 9) Remove the heater core cover. Remove the heater core. (Scheme 10)

Install the heater core. (Scheme 10) Install the heater core cover. (Scheme 9) Install heater core cover screws. Tighten the screws to specification. See TORQUE SPECIFICATIONS. Install the HVAC module. See HVAC MODULE.

Scheme 9

Scheme 9: Installation
Scheme 9: Installation

Scheme 10

Scheme 10
Scheme 10
  1. Remove the HVAC module. See «HVAC MODULE»(ref-152575-S00067383442003021200000). Remove the HVAC module screws. Separate the HVAC module.
  2. Remove the mode actuator or mode cable. Remove the mode actuator cam assembly. (Scheme 8) Remove the heater door cam assembly. Remove the heater door.
  1. Install the heater door cam assembly. Install the mode actuator cam assembly. Install the mode actuator or mode cable. (Scheme 8)
  2. Install the HVAC module halves. Install the HVAC module screws. Tighten the screws to specification. See «TORQUE SPECIFICATIONS»(ref-152575-S17008195592003021200000). Install the HVAC module.
  1. Apply the parking brake to prevent the vehicle from moving. If equipped with an automatic transmission, move the shift lever all the way down to last gear. Tilt the steering wheel to the full down position.
  2. Pull gently rearward on the corners of the bezel from the Instrument Panel (I/P) assembly. Remove the instrument cluster trim plate bezel. (Scheme 11) Remove the instrument panel storage tray. Remove the accessory switch assembly from the instrument panel.
  3. Remove the screws from the HVAC control assembly. Release the HVAC control assembly retaining tabs. Pull the control head out of the instrument panel carrier. (Scheme 12) Disconnect the electrical connectors from the HVAC control assembly. Remove the HVAC control assembly.

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12
  1. Connect the electrical connectors to the HVAC control assembly. Install the HVAC control assembly. (Scheme 12) Install the accessory switch assembly to the instrument panel.
  2. Install the screws from the HVAC control assembly. Tighten the screws to specification. See «TORQUE SPECIFICATIONS»(ref-152575-S17008195592003021200000). Install the instrument panel storage tray. Position the bezel to the I/P assembly. Attach the bezel to the I/P assembly by pushing gently on the bezel till it is in place. (Scheme 11)
  3. Ensure all clips are in place. Tilt the steering wheel to the normal drive position. If equipped with an automatic transmission, move the shift lever to the park position. Disengage the parking brake.
  1. Recover the refrigerant (on A/C equipped vehicles only). See RECOVERY, EVACUATING & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Drain the engine coolant. Reposition the inlet heater hose clamp from the heater core. Remove the inlet heater hose from the heater core.
  2. Reposition the outlet heater hose clamp from the heater core. Remove the outlet heater hose from the heater core. Remove the accumulator (if equipped with A/C). Remove the I/P carrier. See «INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT»(ref-176702-S32310960782005051000000) in INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
  3. Remove the HVAC module drain hose. Disconnect the electrical harnesses and the ground connections. Remove the HVAC module mounting nuts and the screws. Remove the HVAC module assembly from the vehicle. (Scheme 13)

Note. Before installing the HVAC module to the vehicle, ensure that the HVAC module mounting studs are located in the proper positions.

  1. Install the HVAC module assembly to the vehicle Install the HVAC module mounting nuts. Install the HVAC module mounting screws. (Scheme 13) Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-152575-S17008195592003021200000).
  2. Connect the electrical harnesses and the ground connections. Install the HVAC module drain hose. Install the I/P carrier. See «INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT»(ref-176702-S32310960782005051000000) in INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Install the accumulator (if equipped with A/C). Install the outlet heater hose to the heater core. Reposition the outlet heater hose clamp to the heater core.
  3. Install the inlet heater hose to the heater core. Reposition the inlet heater hose clamp to the heater core. Fill the engine coolant. Evacuate and recharge the A/C system. See RECOVERY, EVACUATING & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Leak test the fitting of the repaired component.

Scheme 13

Scheme 13
Scheme 13

Remove the radio. Remove the heater control assembly. See HVAC CONTROL ASSEMBLY. Disconnect the mode cable from the HVAC module. Remove the mode cable from the I/P carrier. (Scheme 14)

Install the mode cable to the I/P carrier. (Scheme 14) Connect the mode cable to the HVAC module. Install the heater control assembly. Install the radio.

Scheme 14

Scheme 14: Installation
Scheme 14: Installation
  1. Remove the floor air outlet duct extension from the floor duct. (Scheme 15) Remove the center console (if equipped). Remove the screws from the center console duct. Remove the center console duct (if equipped).
  2. Disconnect the electrical connection from the mode actuator. Remove the mode actuator mounting screws from the HVAC module. (Scheme 16) Remove the mode actuator as an assembly with the actuator cam. (Scheme 8)
  1. Install the mode actuator as an assembly with the actuator cam. (Scheme 16) Line up the heater/defroster valve lever with the mode actuator cam slot. (Scheme 8) Line up the A/C valve lever with the mode actuator cam.
  2. Install the mode actuator mounting screws to the HVAC module. Tighten the screws to specification. Connect the electrical connection at the mode actuator.
  3. Install the center console duct. Install the screws to the center console duct. Tighten the screws to specification. See «TORQUE SPECIFICATIONS»(ref-152575-S17008195592003021200000). Install the center console. Install the floor air outlet duct extension to the floor air duct.

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16
  1. If equipped, remove the I/P sound insulator. Remove the filter access door screw. (Scheme 17) Remove the filter access door from the HVAC module. Remove the passenger compartment air filter.
  2. Install the passenger compartment air filter. (Scheme 17) Install the filter access door to the HVAC module and tighten the screw. Install the I/P sound insulator, if equipped.

Scheme 17

Scheme 17
Scheme 17
  1. Remove the radio. Remove the heater control assembly. Disconnect the temperature control cable from the HVAC module. (Scheme 18) Remove the temperature control cable from the I/P carrier.
  2. Install the temperature control cable to the I/P carrier. Connect the temperature control cable to the HVAC module. (Scheme 18) Install the heater control assembly. Install the radio.

Scheme 18

Scheme 18
Scheme 18

Remove the HVAC module. See HVAC MODULE. Remove the HVAC module screws. Separate the HVAC module halves. (Scheme 8) Remove the air temperature door.

Install the air temperature door. (Scheme 8) Assemble the HVAC module halves. Install the HVAC module screws. Tighten the screws to specification. See TORQUE SPECIFICATIONS. Install the HVAC module.

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