Defroster Door Replacement
REMOVAL PROCEDURE1. Disconnect the battery negative cable.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
2. Remove the IP lower trim panel.
3. Remove the steering column.
4. Disconnect the left side fuse block from the cross vehicle beam.
5. Remove the retaining screw (1) from the panel air duct.
6. Remove the bolts from the panel air duct.
7. Remove the panel air duct from the cross vehicle beam.
8. Remove the retaining bolts from the right air duct.
9. Remove the right air duct from the cross vehicle beam.
10. Remove the passenger knee bolster bracket.
11. Position the body control module away from the cross vehicle beam.
12. Disconnect any ground wires, as necessary.
13. Remove the brake pedal.
14. Remove the 3 bolts from the brake pedal bracket to cross vehicle beam.
15. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
16. Remove the bolts from the HVAC module center support.
17. Remove the bracket from the HVAC module center support.
18. Reposition the vacuum harness.
19. Remove the bracket bolts from the HVAC module upper support.
20. Remove the bolts from the right and left side of the cross vehicle beam.
21. Remove the cross vehicle beam.
22. Disconnect the two vacuum lines from the defroster actuator (3).
23. Disconnect the orange vacuum line from the recirculation actuator and install a hand vacuum pump (2).
24. Remove the defroster actuator from its attachment to the HVAC module case.
25. Using the hand vacuum pump (2) open the recirculation actuator door.
26. 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.
27. Disconnect the defroster actuator from the defroster door arm.
28. Remove the retaining screws (1) to the air distribution case cover.
29. Remove the air distribution case cover (2).
30. Remove and discard the air distribution case seal.
31. Remove the linkage between the defroster door and the vent door on the left side of the HVAC module assembly.
32. 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 retaining screws (1) to the air distributor cover.
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 to the right and left side of the cross vehicle beam.
16. Tighten the bolts to the right and left side of the cross vehicle beam in sequence.
Tighten
Tighten the bolts to 25 N.m (18 lb ft).
17. Install the bracket bolts to the HVAC module upper support.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
18. Install the passenger knee bolster bracket.
19. Install the bracket to the HVAC module center support.
20. Reposition the vacuum harness to the original position.
21. Install the bracket bolts to the HVAC module center support.
22. Tighten the bracket bolts in sequence as shown.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
23. Reposition the IP wiring harness to the cross vehicle beam and secure the retaining clips.
24. Install the 3 bolts through the brake pedal bracket to the cross vehicle beam.
Tighten
Tighten the bolts to 50 N.m (37 lb ft).
25. Install the brake pedal.
26. Connect all disconnected ground wires.
27. Reposition the body control module in place.
28. Install the fuse blocks to the cross vehicle beam.
29. Install the right air duct to the cross vehicle beam.
30. Install the right air duct bolts.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
31. Install the panel air duct to the cross vehicle beam.
32. Install the panel air duct screw (1).
Tighten
Tighten the bolts to 1.8 N.m (16 lb in).
33. Install the panel air duct bolts.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
34. Install the steering column.
35. Install the lower trim panel.
36. Connect the battery negative cable.