HVAC System - Automatic: Removal & Installation Chevrolet Silverado Classic 1500 HD

Removal Procedure

1. Remove the instrument panel accessory trim plate. Refer to «Instrument Panel Cluster Trim Plate Bezel Replacement»(ref-277842-S21990475722008012100000) .
2. Remove the screws from the HVAC control module.
3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel.
4. Disconnect the electrical connectors from the HVAC control module.

Installation Procedure

1. Connect the electrical connectors to the HVAC control module.
2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place.
3. Install the screws from the HVAC control module. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
4. Install the instrument panel accessory trim plate. Refer to «Instrument Panel Cluster Trim Plate Bezel Replacement»(ref-277842-S21990475722008012100000) .
5. Start the vehicle and let run for one minute.
6. Refer to «Control Module References»(ref-277885-S04826892822008012100000) for programming and setup information.

1. If equipped, remove the sound insulator panel. Refer to «Instrument Panel Insulator Replacement»(ref-277842-S25943633462008012100000) .
2. Disconnect the electrical connector at the blower motor.
3. Disconnect the electrical connector (4) from the blower motor control processor (2).
4. Remove the blower motor control processor retaining screws (3) from the HVAC module (1).
5. Remove the blower motor control processor (2) from the HVAC module (1).

1. Install the blower motor control processor (2) to the HVAC module (1).
2. Install the blower motor control processor retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
3. Connect the electrical connector (4) to the blower motor control processor (2).
4. Connect the electrical connector at the blower motor.
5. If equipped, install the sound insulator panel. Refer to «Instrument Panel Insulator Replacement»(ref-277842-S25943633462008012100000) .

Note. In order to avoid actuator damage, DO NOT apply power to the actuator when it is not installed in the HVAC module.

1. Remove the air distribution duct. Refer to «Air Distributor Duct Replacement»(ref-277853-S16945701282008012100000) .
2. Disconnect the electrical connection from the recirculation actuator (1).
3. Remove the recirculation actuator retaining screws.
4. Remove the recirculation actuator.

1. Install the recirculation actuator.
2. Install the recirculation actuator retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
3. Connect the electrical connector to the recirculation actuator (1).
4. Install the air distribution duct. Refer to «Air Distributor Duct Replacement»(ref-277853-S16945701282008012100000) .

Note. In order to avoid actuator damage, DO NOT apply power to the actuator when it is not installed in the HVAC module.

1. Remove the floor air outlet duct extension (1) from the floor duct (2).
2. Remove the center console. Refer to «Console Replacement (w/Console Mounting)»(ref-277842-S05891944102008012100000) or «Console Replacement (w/o Console Mounting)»(ref-277842-S25901382862008012100000) .
3. Remove the screws from the center console duct.
4. Remove the center console duct.
5. Disconnect the electrical connection from the mode actuator (10).
6. Remove the mode actuator mounting screws from the HVAC module.
7. Remove the mode actuator as an assembly with the actuator cam.

1. Install the mode actuator as an assembly with the actuator cam. Line up the heater/defroster valve lever with the mode actuator cam slot. Line up the A/C valve lever with the mode actuator cam.
2. Install the mode actuator mounting screws to the HVAC module. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
3. Connect the electrical connection at the mode actuator (10).
4. Install the center console duct.
5. Install the screws to the center console duct. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
6. Install the center console. Refer to «Console Replacement (w/Console Mounting)»(ref-277842-S05891944102008012100000) or «Console Replacement (w/o Console Mounting)»(ref-277842-S25901382862008012100000) .
7. Install the floor air outlet duct extension (1) to the floor air duct (2).

Note. In order to avoid actuator damage, DO NOT apply power to the actuator when it is not installed in the HVAC module.

1. Remove the floor air outlet duct extension (1) from the floor duct (2).
2. Remove the body control module. Refer to «Body Control Module Replacement»(ref-277861-S16446328882008012100000) .
3. Disconnect the electrical connection at the mode actuator (10).
4. Remove the mode actuator mounting screws from the HVAC module.
5. Remove the mode actuator as an assembly with the actuator cam.

1. Install the mode actuator as an assembly with the actuator cam. Line up the heater/defroster lever with the mode actuator cam slot. Line up the A/C lever with the mode actuator cam.
2. Install the mode actuator mounting screws to the HVAC module. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
3. Connect the electrical connection at the mode actuator (10).
4. Install the body control module. Refer to «Body Control Module Replacement»(ref-277861-S16446328882008012100000) .
5. Install the floor air outlet duct extension (1) to the floor air duct (2).

Note. In order to avoid actuator damage, DO NOT apply power to the actuator when it is not installed in the HVAC module.

1. Remove the I/P carrier. Refer to «Instrument Panel Carrier Replacement»(ref-277842-S12657646732008012100000) .
2. Disconnect the electrical connector (4) from the right air temperature actuator (3).
3. Remove the screws from the right air temperature actuator (3).
4. Remove the right air temperature actuator (3) from the HVAC module assembly (2).

1. Install the right air temperature actuator (3) from the HVAC module assembly (2).
2. Install the screws to the right air temperature actuator (3). Tighten: Tighten the screws to 2 N.m (18 lb in).
3. Connect the electrical connector to the right air temperature actuator.
4. Install the I/P carrier. Refer to «Instrument Panel Carrier Replacement»(ref-277842-S12657646732008012100000) .
5. Reprogram the air temperature actuator. Refer to «Actuator Recalibration»(ref-277856-S14092445702008012100000) .

Note. In order to avoid actuator damage, DO NOT apply power to the actuator when it is not installed in the HVAC module.

1. Remove the center console, if equipped. Refer to «Console Replacement (w/Console Mounting)»(ref-277842-S05891944102008012100000) or «Console Replacement (w/o Console Mounting)»(ref-277842-S25901382862008012100000) .
2. Remove the instrument panel (I/P) insulator panel. Refer to «Instrument Panel Insulator Replacement»(ref-277842-S25943633462008012100000) .
3. Disconnect the electrical connector (1) from the left air temperature actuator (2).
4. Remove the screws from the left air temperature actuator (2).
5. Remove the left air temperature actuator (2) from the HVAC module assembly (3).

1. Install the left air temperature actuator (2) to the HVAC module assembly (3).
2. Install the screws to the left air temperature actuator (2). Tighten: Tighten the screws to 2 N.m (18 lb ft).
3. Install the electrical connector (1) to the left air temperature actuator (2).
4. Install the I/P insulator panel. Refer to «Instrument Panel Insulator Replacement»(ref-277842-S25943633462008012100000) .
5. Install the center console, if equipped. Refer to «Console Replacement (w/Console Mounting)»(ref-277842-S05891944102008012100000) or «Console Replacement (w/o Console Mounting)»(ref-277842-S25901382862008012100000) .
6. Reprogram the left air temperature actuator. Refer to «Actuator Recalibration»(ref-277856-S14092445702008012100000) .

1. Remove the I/P upper trim panel. Refer to «Instrument Panel Upper Trim Panel Replacement»(ref-277842-S24002983362008012100000) ..
2. Disconnect the electrical connector (1) from the upper right air temperature sensor (2).
3. Remove the upper right air temperature sensor (1) from the air distributor duct (3).

1. Install the upper right air temperature sensor (1) to the air distributor duct (3).
2. Connect the electrical connector (1) from the upper right air temperature sensor (2).
3. Install the I/P upper trim panel. Refer to «Instrument Panel Upper Trim Panel Replacement»(ref-277842-S24002983362008012100000) .

1. Remove the upper left air temperature sensor (2) from the air distributor duct (1).
2. Disconnect the electrical connector (3) from the upper left air temperature sensor (2).

1. Install the upper left air temperature sensor (2) to the air distributor duct (1).
2. Connect the electrical connector (3) to the upper left air temperature sensor (2).

1. Disconnect the electrical connector from the lower left air temperature sensor (1).
2. Remove the lower left air temperature sensor (1) from the HVAC module (2).

1. Install the lower left air temperature sensor (1) to the HVAC module (2).
2. Connect the electrical connector to the lower left air temperature sensor (1).

1. Remove the I/P lower closeout panel. Refer to «Instrument Panel Insulator Replacement»(ref-277842-S25943633462008012100000) .
2. Remove the right floor duct. Refer to «Floor Air Outlet Duct Replacement - Right Side»(ref-277853-S24765236032008012100000) .
3. Remove the center console. Refer to «Console Replacement (w/Console Mounting)»(ref-277842-S05891944102008012100000) or «Console Replacement (w/o Console Mounting)»(ref-277842-S25901382862008012100000) .
4. Disconnect the electrical connector from the lower right air temperature sensor (1).
5. Remove the lower right air temperature sensor (1).

1. Install the lower right air temperature sensor (1).
2. Connect the electrical connector to the lower right air temperature sensor (1).
3. Install the center console. Refer to «Console Replacement (w/Console Mounting)»(ref-277842-S05891944102008012100000) or «Console Replacement (w/o Console Mounting)»(ref-277842-S25901382862008012100000) .
4. Install the right floor duct. Refer to «Floor Air Outlet Duct Replacement - Right Side»(ref-277853-S24765236032008012100000) .
5. Install the I/P lower closeout panel. Refer to «Instrument Panel Insulator Replacement»(ref-277842-S25943633462008012100000) .

1. Remove the park/turn signal. Refer to «Park/Turn Signal Lamp Replacement (Old Style)»(ref-277846-S12129221692008012100000) .
2. Disconnect the electrical connector from the ambient air temperature sensor (3).
3. Remove the ambient air temperature sensor (3).

1. Install the ambient air temperature sensor (3).
2. Connect the electrical connector to the ambient air temperature sensor (3).
3. Install the park/turn signal. Refer to «Park/Turn Signal Lamp Replacement (Old Style)»(ref-277846-S12129221692008012100000) .

1. Remove the left windshield garnish molding. Refer to «Windshield Pillar Garnish Molding Replacement»(ref-277840-S23920638912008012100000) .
2. Remove the left center pillar assist handle. Refer to «Roof Rail Rear Assist Handle Replacement»(ref-277840-S19771833452008012100000) .
3. Remove the left center pillar garnish molding. Refer to «Center Pillar Garnish Molding Replacement»(ref-277840-S40020983572008012100000) .
4. Remove the left sunshade. Refer to «Sunshade Replacement»(ref-277840-S01999992732008012100000) .
5. Gently pull down the headliner.
6. Disconnect the electrical connector from the inside air temperature sensor.
7. Partially remove the inside air temperature sensor from the headliner.
8. Remove the sensor grille from the inside air temperature sensor.
9. Remove the inside air temperature sensor from the headliner.

1. Install the new sensor grille to the headliner.
2. Install the inside air temperature sensor to the headliner and sensor grille.
3. Connect the electrical connector to the inside air temperature sensor.
4. Install the left sunshade. Refer to «Center Pillar Garnish Molding Replacement»(ref-277840-S40020983572008012100000) .
5. Install the left center pillar garnish molding. Refer to «Center Pillar Garnish Molding Replacement»(ref-277840-S40020983572008012100000) .
6. Install the left center assist handle. Refer to «Roof Rail Rear Assist Handle Replacement»(ref-277840-S19771833452008012100000) .
7. Install the left windshield garnish molding. Refer to «Windshield Pillar Garnish Molding Replacement»(ref-277840-S23920638912008012100000) .

1. Remove the instrument panel (I/P) upper trim panel. Refer to «Instrument Panel Upper Trim Panel Replacement»(ref-277842-S24002983362008012100000) ..
2. Remove the sun load sensor (2) from the upper trim panel.
3. Disconnect the electrical connector.

1. Connect the electrical connector.
2. Install the sun load sensor (2) to the upper trim panel.
3. Install the I/P upper trim panel. Refer to «Instrument Panel Upper Trim Panel Replacement»(ref-277842-S24002983362008012100000) ..