I have not done this on my HHR, but I did do it on an older GM my daughter owned. It was pretty much the same thing, cut the plastic to remove the blower motor. It looks worse than it is. The plastic you need to cut is not as thick as you might think. As said use a brand new blade and take your time.

 

Thanks guys. I got the old motor out last night after work, got the cover off and attached to the new motor and attached the mounting ring. But it was getting too dark to try and mount it all back under the dash, so I will have to try that today.

 

While you are down there take a look at the resistor also. Mine needed replacing.

 

How would I know it needs replacement?

 

It will look a bit burned. These used be a high failure rate item. I've replaced them on many GMs that I and my family have owned. Doesn't seem to be a problem on the HHR but it's certainly worth a look. And they are not expensive, maybe $20 or so.

 

If the resister has failed you will have only high speed fan. 2006 models have a problem with water dripping on it and the motor from a failed patch under the cowl.

 

I currently have all speeds, but I will check it while I have the cover off. Looks like $45 at AutoZone.

 

Grrr... Tried screwing the new motor during my lunch break. Can't manage to a) hold the blower up in place, b) get drill in position without c) dropping tiny hex head nut out of socket in adapter while upside down under the dash.
It sucks getting old.

 

How about a magnetic socket?

 

I need to buy a set.
I finally managed to get two of the three screws in and got it plugged in for a test drive. Working great!
Resistor looks clean. I will try to get the last screw in tomorrow.