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Home/Chevrolet/Tahoe/Chevrolet Tahoe II (1999-2006)/Repair manual/Automatic HVAC System/HVAC Systems - Automatic: Removal & Installation
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HVAC Systems - Automatic: Removal & Installation Chevrolet Tahoe II

Automatic HVAC System ~2061 words

Removal Procedure

  1. Remove the instrument panel accessory trim plate. Refer to «BEZEL REPLACEMENT - IP CLUSTER»(ref-175346-S10239601372005042000000) .
  2. Remove the accessory switch from the instrument panel. Refer to «ACCESSORY SWITCH REPLACEMENT»(ref-175346-S20342488302005042000000) .
  3. Remove the screws from the HVAC control module.
  4. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel.
  5. 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.
  3. Install the screws to the HVAC control module. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  4. Install the accessory switch to the instrument panel. Refer to «ACCESSORY SWITCH REPLACEMENT»(ref-175346-S20342488302005042000000) .
  5. Install the instrument panel accessory trim plate. Refer to «BEZEL REPLACEMENT - IP CLUSTER»(ref-175346-S10239601372005042000000) .
  1. Remove the console roof screw.
  2. Remove the console (1) from the headliner.
  3. Disconnect the electrical connectors (3) from the console (1).
  4. Remove the console (1) from the vehicle.
  5. Remove the HVAC control assembly (2) from the console (1) by depressing the 4 tabs on the back of the HVAC control assembly (2).
  1. Install the HVAC control assembly (2) to the console (1).
  2. Connect the electrical connectors (3) to the console (1).
  3. Install the console (1) to the headliner.
  4. Install the overhead console screw. Tighten: Tighten the screw to 2 N.m (18 lb in).
  1. Separate the front of the console (1) from the headliner by pushing forward and pulling down in the front.
  2. Remove the HVAC control assembly (2) by releasing the tabs at the rear of the HVAC control module. Push out from the back through the console.
  3. Disconnect the electrical connector (3) from the HVAC control module.
  1. Connect the electrical connector (3) to the HVAC control module.
  2. Install the HVAC control module (2) to the console (1).
  3. Install the console to the headliner.
  1. If equipped, remove the sound insulator panel. Refer to «INSULATOR REPLACEMENT - IP»(ref-175346-S29605562292005042000000) .
  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 «INSULATOR REPLACEMENT - IP»(ref-175346-S29605562292005042000000) .
  1. Remove the right rear quarter trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  2. Disconnect the electrical connector from the auxiliary blower motor processor (1).
  3. Remove the retaining screws from the auxiliary blower motor processor (1).
  4. Remove the auxiliary blower motor processor (1) from the auxiliary HVAC module (2).
  1. Install the auxiliary blower motor processor (1) to the auxiliary HVAC module (2).
  2. Install the retaining screws to the auxiliary blower motor processor (1). Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Connect the electrical connector to the auxiliary blower motor processor (1).
  4. Install the right rear quarter trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  1. Remove the air distribution duct.
  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.
  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-176074-S33825007552005042900000) .
  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-176074-S33825007552005042900000) .
  5. Install the floor air outlet duct extension (1) to the floor air duct (2).
  1. Remove the floor air outlet duct extension (1) from the floor duct (2).
  2. Remove the center console. Refer to «CONSOLE REPLACEMENT (BASE CONSOLE)»(ref-175346-S13243043262005042000000) or «CONSOLE REPLACEMENT (LUXURY CONSOLE)»(ref-175346-S31160802872005042000000) .
  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 (BASE CONSOLE)»(ref-175346-S13243043262005042000000) or «CONSOLE REPLACEMENT (LUXURY CONSOLE)»(ref-175346-S31160802872005042000000) .
  7. Install the floor air outlet duct extension (1) to the floor air duct (2).
  1. Remove the IP insulator. Refer to «INSULATOR REPLACEMENT - IP»(ref-175346-S29605562292005042000000) .
  2. Disconnect the electrical connector (8) from the air temperature actuator (9).
  3. Remove the air temperature actuator retaining screws.
  4. Remove the air temperature actuator.
  1. Install the air temperature actuator.
  2. Install the air temperature actuator retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Connect the electrical connector (8) to the air temperature actuator (9).
  4. Install the IP insulator. Refer to «INSULATOR REPLACEMENT - IP»(ref-175346-S29605562292005042000000) .
  1. Remove the right rear quarter trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  2. Disconnect the electrical connector from the auxiliary air temperature actuator.
  3. Remove the retaining screws from the auxiliary air temperature actuator.
  4. Remove the auxiliary air temperature actuator (1) from the rear auxiliary HVAC module.
  1. Install the auxiliary air temperature actuator (1) to the auxiliary HVAC module.
  2. Install the auxiliary air temperature actuator retaining screws. Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Connect the electrical connector to the auxiliary air temperature actuator.
  4. Install the right rear quarter trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  1. Remove the right rear quarter trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  2. Disconnect the electrical connector from the mode actuator (1).
  3. Remove the retaining screws from the mode actuator.
  4. Remove the mode actuator (1) from the vehicle.
  1. Install the mode actuator (1) to the vehicle.
  2. Install the screws to the mode actuator (1). Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Connect the electrical connector to the mode actuator.
  4. Install the left rear quarter trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  1. Remove the right rear quarter trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  2. Disconnect the electrical connector from the mode actuator (1).
  3. Remove the retaining screws from the mode actuator.
  4. Remove the mode actuator (1) from the vehicle.
  1. Install the mode actuator (1) to the vehicle.
  2. Install the screws to the mode actuator (1). Tighten: Tighten the screws to 1.6 N.m (14 lb in).
  3. Connect the electrical connector to the mode actuator.
  4. Install the right rear quarter trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  1. Remove the radio. Refer to «RADIO REPLACEMENT»(ref-176018-S03035083602005042900000) .
  2. Disconnect the electrical connector from the upper duct air temperature sensor.
  3. Remove the upper duct air temperature sensor from the air duct by prying out of the duct.
  1. Install the upper duct air temperature sensor to the air duct.
  2. Connect the electrical connector to the upper duct air temperature sensor.
  3. Install the radio. Refer to «RADIO REPLACEMENT»(ref-176018-S03035083602005042900000) .
  1. Remove the right side C-pillar trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  2. Disconnect the electrical connector from the rear upper A/C temperature sensor (11).
  3. Remove the rear upper A/C temperature sensor (11) from the air distribution duct.
  1. Install the rear upper A/C temperature sensor (11) to the air distribution duct.
  2. Connect the electrical connector to the rear upper A/C temperature sensor (11).
  3. Install the right side C-pillar trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  1. Remove the lower duct air temperature sensor (3) and wiring harness assembly from the floor air outlet (2).
  2. Disconnect the electrical connector from the lower duct air temperature sensor (3).
  1. Connect the lower duct air temperature sensor (3) to the electrical connector.
  2. Install the lower duct air temperature sensor (3) and wiring harness assembly to the floor air outlet (2).
  1. Remove the right side C-pillar trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  2. Disconnect the electrical connector from the auxiliary lower A/C temperature sensor (10).
  3. Remove the auxiliary lower A/C temperature sensor (10) from the air distribution duct.
  1. Install the rear lower A/C temperature sensor (10) to the air distribution duct.
  2. Connect the electrical connector to the rear lower A/C temperature sensor (10).
  3. Install the right side C-pillar trim panel. Refer to «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (UTILITY)»(ref-176028-S10691982822005042900000) or «TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (SUBURBAN)»(ref-176028-S03147008052005042900000) .
  1. Remove the Park/Turn Signal. Refer to «PARK/TURN SIGNAL LAMP REPLACEMENT (EXCEPT AVALANCHE)»(ref-175710-S24701445912005042600000) or «PARK/TURN SIGNAL LAMP REPLACEMENT (AVALANCHE)»(ref-175710-S00829657042005042600000) .
  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 (EXCEPT AVALANCHE)»(ref-175710-S24701445912005042600000) or «PARK/TURN SIGNAL LAMP REPLACEMENT (AVALANCHE)»(ref-175710-S00829657042005042600000) .
  1. Remove the left windshield garnish molding. Refer to «GARNISH MOLDING REPLACEMENT - WINDSHIELD PILLAR»(ref-176028-S31334655382005042900000) .
  2. Remove the left center pillar assist handle. Refer to «ASSIST HANDLE REPLACEMENT - REAR»(ref-176028-S29426151192005042900000) .
  3. Remove the left center pillar garnish molding. Refer to «GARNISH MOLDING REPLACEMENT - CENTER PILLAR»(ref-176028-S33504993562005042900000) .
  4. Remove the left sunshade. Refer to «SUNSHADE REPLACEMENT»(ref-176028-S42883744692005042900000) .
  5. Remove the retaining screws from the headliner.
  6. Gently pull down the headliner.
  7. Remove the inside air temperature sensor from the headliner.
  8. Disconnect the electrical connector from the inside air temperature sensor.
  9. Remove the inside air temperature sensor from the headliner.
  1. Install the inside air temperature sensor to the headliner.
  2. Connect the electrical connector to the inside air temperature sensor.
  3. Install the screws to the headliner.
  4. Install the left sunshade. Refer to «SUNSHADE REPLACEMENT»(ref-176028-S42883744692005042900000) .
  5. Install the left center pillar garnish molding. Refer to «GARNISH MOLDING REPLACEMENT - CENTER PILLAR»(ref-176028-S33504993562005042900000) .
  6. Install the left center assist handle. Refer to «ASSIST HANDLE REPLACEMENT - REAR»(ref-176028-S29426151192005042900000) .
  7. Install the left windshield garnish molding. Refer to «GARNISH MOLDING REPLACEMENT - WINDSHIELD PILL»(ref-176028-S31334655382005042900000) .
  1. Remove the instrument panel (I/P) upper trim panel. Refer to «TRIM PANEL REPLACEMENT - INSTRUMENT PANEL (IP) UPPER»(ref-175346-S38271644542005042000000) .
  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 «TRIM PANEL REPLACEMENT - INSTRUMENT PANEL (IP) UPPER»(ref-175346-S38271644542005042000000) .

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