Defroster Door Replacement
REMOVAL PROCEDURE1. Remove the instrument panel trim pad.
2. Remove the passenger side SIR inflator module.
3. Remove the brake pedal.
4. Disconnect any ground wires, as necessary.
5. Remove the nuts and bolts from the steering column support bracket.
6. Remove the steering column support bracket from the cross vehicle beam.
7. Remove the screws from the right and left side air distribution ducts.
8. Remove the air distribution ducts.
9. Remove the bolts from the relay bracket and position the relay bracket aside.
10. Remove the bolts from the BCM bracket and position the BCM bracket aside.
11. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
12. Remove the two screws below the fuse block that hold the main harness connector to the cross vehicle beam.
13. Remove the bolts from the center support bracket of the HVAC module.
14. Remove the center support bracket of the HVAC module.
15. Remove the bolts from the upper support brackets of the HVAC module.
16. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.
17. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.
18. Remove the bolt (1) from the cross vehicle beam.
19. Remove the cross vehicle beam from the vehicle.
20. Disconnect the 2 vacuum lines from the defroster actuator (3).
21. Disconnect the orange vacuum line from the recirculation actuator and install a hand vacuum pump (2).
22. Remove the defroster actuator from the attachment to the HVAC module case.
23. Using the hand vacuum pump (2) open the recirculation actuator door.
24. Rotate the defroster actuator to the right and up into the opening between the back of the dash and the opening into the HVAC module. The opening which results when the recirculation actuator door is in the full open position.
25. Disconnect the defroster actuator from the defroster door arm.
26. Remove the retaining screws (1) from the air distribution case cover.
27. Remove the air distribution case cover (2).
28. Remove and discard the air distribution case seal.
29. Remove the linkage between the defroster door and the vent door on the left side of the HVAC module assembly.
30. Remove the defroster door (1).
INSTALLATION PROCEDURE
1. Install the defroster door (1).
IMPORTANT: Align the defroster door assist spring to the HVAC module assembly case.
2. Connect the linkage between the defroster door and the vent door.
3. Install a new air distribution case seal.
4. Install the air distribution case cover (2).
5. Install the air distributor cover retaining screws (1).
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the screws to 1.5 N.m (13 lb in).
6. Connect the orange vacuum line to a hand vacuum pump (2).
7. Using the hand vacuum pump (2) open the recirculation actuator door.
8. Rotate the defroster actuator to the right and up into the opening between the back of the dash and the opening into the HVAC module. The opening which results when the recirculation actuator door is in the full open position.
9. Connect the defroster actuator to the defroster door arm.
10. Position the defroster actuator on to the mounting slides of the HVAC module assembly.
11. Ensure that the lock tab locks the defroster actuator in place.
12. Connect the vacuum lines to the defroster actuator.
13. Connect the vacuum line to the recirculation actuator.
14. Install the cross vehicle beam to the vehicle.
15. Install the bolts which secure the right cross vehicle beam to the hinge pillar. Tighten the bolts finger tight.
16. Install the bolts which secure the left cross vehicle beam to the hinge pillar. Tighten the bolts finger tight.
Tighten
Tighten all the bolts to 20 N.m (15 lb ft).
17. Install the bolt (1) to the cross vehicle beam.
Tighten
Tighten the bolt to 20 N.m (15 lb ft).
18. Install the bolts to the upper support brackets of the HVAC module.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
19. Install the center support bracket to the HVAC module.
20. Install the bolts to the center support bracket of the HVAC module.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
21. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.
22. Install the two screws below the fuse block that hold the main wire harness connector to the cross vehicle beam.
23. Install the BCM bracket and the bolts.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
24. Install the relay bracket and the bolts.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
25. Install the right and left side air distribution duct bolts.
Tighten
Tighten the bolts to 1.5 N.m (13 lb in).
26. Install the steering column support bracket to the cross vehicle beam.
27. Install the nuts and bolts to the steering column support bracket.
Tighten
Tighten the nuts and bolts to 50 N.m (37 lb ft).
28. Install the brake pedal.
29. Connect all disconnected ground wires.
30. Install the passenger side SIR inflator module.
31. Install the instrument panel trim pad.