GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 2004 🢒 Regal 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Defroster Air Outlet Replacement

Removal Procedure
  1. Remove the instrument panel trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gages, and Console.
  2. Remove the passenger side SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
  3. Remove the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  4. Remove the bolts from the steering column support bracket and remove the bracket.
  5. Remove the air distribution duct from the cross vehicle beam. Refer to Air Distributor Duct Replacement .

    6. Object Number: 486677 Size: SH
  6. Remove the bolts from the relay bracket and position the relay bracket aside.

    7. Object Number: 486680 Size: SH
  7. Remove the bolts from the BCM bracket and position the BCM bracket aside.
  8. Release the wiring harness retaining clips from the cross vehicle beam and position the instrument panel wiring harness aside.
  9. Remove the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam.

    10. Object Number: 282301 Size: SH
  10. Remove the bolts from the center support bracket of the HVAC module.
  11. Remove the center support bracket from the HVAC module.

    12. Object Number: 482597 Size: SH
  12. Remove the bolts from the upper support brackets of the HVAC module.

    13. Object Number: 482587 Size: SH
  13. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.

    14. Object Number: 482588 Size: SH
  14. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.

    15. Object Number: 811571 Size: SH
  15. Remove the bolt (1) from the cross vehicle beam.
  16. Remove the cross vehicle beam from the vehicle.

    17. Object Number: 176880 Size: SH
  17. Remove the defroster duct mounting screws.
  18. Remove the defroster duct.

Installation Procedure

    Object Number: 176880 Size: SH
  1. Install the defroster duct.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the mounting screws.

    3. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  3. Install the defrost distribution ducts to the cross vehicle beam. Refer to Defroster Air Outlet Replacement .

    4. Object Number: 482600 Size: SH
  4. Install the cross vehicle beam to the vehicle.

    5. Object Number: 482588 Size: SH
  5. Install the bolts which secure the right cross vehicle beam to the hinge pillar. Tighten the bolts finger tight.

    6. Object Number: 482587 Size: SH
  6. Install the bolts which secure the left cross vehicle beam to the hinge pillar.

    7. Tighten
    Tighten all hinge pillar bolts to 20 N·m (15 lb ft).


    Object Number: 811571 Size: SH
  7. Install the bolt (1) to the cross vehicle beam.

    8. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 482597 Size: SH
  8. Install the bolts to the upper support brackets of the HVAC module.

    9. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 282301 Size: SH
  9. Install the center support bracket to the HVAC module.
  10. Install the bolts to the center support bracket of the HVAC module.

    11. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  11. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.
  12. Install the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam.

    13. Object Number: 486680 Size: SH
  13. Install the BCM bracket and the bolts.

    14. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 486677 Size: SH
  14. Install the relay bracket and the bolts.

    15. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  15. Install the air distribution ducts to the cross vehicle beam. Refer to Air Distributor Duct Replacement .

    16. Object Number: 637312 Size: SH
  16. Install the support bracket for the steering column.

    17. Tighten
    Tighten the nuts to 50 N·m (37 lb ft).

  17. Install the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  18. Install the passenger side SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
  19. Install the instrument panel trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gages, and Console.