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HVAC Case replacement 06 COBALT
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Oberschmidt93
New User
Aug 11, 2015, 7:10 PM
Post #1 of 4
(2174 views)
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HVAC Case replacement 06 COBALT
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I have a 2006 Chevrolet Cobalt LS, 2.2 Engine. I have a broken piece on the blend door for the actuator to work. I am looking at going to a junk yard tomorrow to get a entire case assembly.. Does anyone know where I can find specific instructions on how to do this?
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Hammer Time
Ultimate Carjunky
/ Moderator
Aug 12, 2015, 2:12 AM
Post #2 of 4
(2156 views)
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Re: HVAC Case replacement 06 COBALT
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HVAC MODULE ASSEMBLY REPLACEMENT
TOOLS REQUIRED
- J 39400-A Halogen Leak Detector
- J 38185 Hose Clamp Pliers
CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.
REMOVAL PROCEDURE
- Disconnect the negative battery cable.
- Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
- Drain the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5)) Draining and Filling Cooling System (GE 47716 Fill) in Cooling System.
- Reposition the heater outlet hose clamp at the heater core using J 38185.
- Remove the heater outlet hose from the heater core.
- Position the hose upright against the front of dash.
- Reposition the heater inlet hose clamp at the heater core using J 38185.
- Remove the heater inlet hose from the heater core.
- Position the hose upright against the front of dash.
- Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
- Remove and discard the seal washers.
- Remove the HVAC module nuts from the front of dash.
- Disconnect the blower motor connector.
- Disconnect the blower motor resister electrical connector.
- Remove the instrument panel (I/P) tie bar.
- Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts.
- Rotate the center floor outlet duct forward in the vehicle and pull down to disengage the duct from the HVAC module.
- Disconnect the recirculation actuator electrical connector.
- Remove the HVAC module from the vehicle.
INSTALLATION PROCEDURE
- Replace the drain tube seal.
- Replace the front of dash seal.
- Inspect and replace the HVAC module seals if damaged:
- The defrost duct seal
- The HVAC module to cross car duct seal
- The center air outlet duct seal
- The center floor air outlet duct seal
- The air inlet seal
- Place the HVAC module in the vehicle. Align the HVAC module drain tube and front of dash studs to the vehicle.
- Install the HVAC module nuts to the front of dash.
Tighten the nuts to 10 N.m (89 lb in) .
NOTE: Refer to Fastener Notice in Service Precautions.
- Connect the recirculation actuator electrical connector.
- Align the center floor duct with the HVAC module.
- Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module.
- Push down on the floor duct while rotating the center floor outlet ducts to align the ducts.
- Slide the center floor outlet duct down into position in the floor ducts.
- Install the I/P tie bar.
- Connect the blower motor connector.
- Connect the blower motor resister electrical connector.
- Install the heater outlet hose to the heater core.
- Reposition the hose clamp to secure the hose using J 38185.
- Install the heater inlet hose to the heater core.
- Reposition the hose clamp to secure the hose using J 38185.
- Install new sealing washers on the condenser tube and evaporator hose fittings.
- Install the condenser tube and evaporator hose to the TXV.
- Install the TXV nut.
Tighten the nut to 20 N.m (15 lb ft) .
- Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
- Leak test the fittings using the J 39400-A.
- Connect the negative battery cable.
- Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5)) Draining and Filling Cooling System (GE 47716 Fill) in Cooling System.
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
(This post was edited by Hammer Time on Aug 12, 2015, 2:15 AM)
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Discretesignals
Ultimate Carjunky
/ Moderator
Aug 12, 2015, 4:48 AM
Post #3 of 4
(2146 views)
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Re: HVAC Case replacement 06 COBALT
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Got part of the procedure. The tie bar has to come out which means you have to remove the entire dash. Maybe the OP should subscribe to AlldataDIY cause there are lots of steps in removal and installation. It's an 8 hour job to remove and install one. Going to have fun laying on the seats in the middle of a salvage yard getting that one out..yuck.
Since we volunteer our time and knowledge, we ask for you to please follow up when a problem is resolved.
(This post was edited by Discretesignals on Aug 12, 2015, 4:49 AM)
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Hammer Time
Ultimate Carjunky
/ Moderator
Aug 12, 2015, 6:40 AM
Post #4 of 4
(2138 views)
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Re: HVAC Case replacement 06 COBALT
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They didn't leave it out.
3rd from the last paragraph in removal section. "Remove Instrument Panel"
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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