GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Oldsmobile 🢒 2002 🢒 Intrigue 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Defroster Door Replacement

Removal Procedure

    Object Number: 486677 Size: SH
  1. Remove the instrument panel trim pad. Refer to Instrument Panel Trim Pad Replacement in instrument Panel, Gages and Controls.
  2. Remove the passenger SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
  3. Remove the brake pedal. Refer to Brake Pedal Replacement in Hydraulic Brakes.
  4. Remove the bolts from the steering column support bracket and remove the bracket.
  5. Remove the bolts retaining the relay bracket and reposition the bracket.

    6. Object Number: 283722 Size: SH
  6. Remove the screws from the right and left side air distributor duct.
  7. Remove the right and left side air distributor duct.

    8. Object Number: 486680 Size: SH
  8. Remove the bolts retaining the BCM bracket and reposition the BCM bracket aside.

    9. Object Number: 282301 Size: SH
  9. Remove the bolts which secure the center support bracket of the HVAC module.
  10. Remove the center support bracket of the HVAC module.
  11. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness out of the way.
  12. Remove the two screws below the fuse block that hold the main wire harness connector to the cross vehicle beam.

    13. Object Number: 482597 Size: SH
  13. Remove the bolts which retain the HVAC module to the cross vehicle beam.

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

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

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

    17. Object Number: 482600 Size: SH
  17. Remove the cross vehicle beam from the vehicle.
  18. Remove the defroster actuator.
  19. Remove the mode actuator.

    20. Object Number: 607130 Size: SH
  20. Remove the retaining screws (1) which secure the air distribution case cover.
  21. Remove the air distribution case cover (2).
  22. Remove and discard the air distribution case seal.
  23. Remove the linkage between the defroster door and the heater door on the left side of the HVAC module.

    24. Object Number: 607136 Size: SH
  24. Remove the defroster door (1).

Installation Procedure

    Object Number: 607136 Size: SH

    Important: Align the defroster door assist spring to the HVAC module assembly case.

  1. Install the defroster door (1).
  2. Connect the linkage between the defroster door and the heater door.
  3. Install a new air distribution case seal.

    4. Object Number: 607130 Size: SH
  4. Install the air distribution case cover (2).

    5. 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.

  5. Install the retaining screws (1) which secure the air distributor cover.

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

  6. Install the defroster actuator.
  7. Install the mode actuator.

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

    9. Object Number: 482588 Size: SH

    Important: Do not tighten bolts until you have installed all of the bolts.

  9. Install the cross vehicle beam to the right hinge pillar with the retaining bolts, but do NOT tighten.

    10. Object Number: 482587 Size: SH
  10. Install the cross vehicle beam to the left hinge pillar with the retaining bolts.
  11. Tighten the bolts retaining the cross vehicle beam to both the left and the right hinge pillars.

    12. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 482597 Size: SH
  12. Install the bolt (1) to the cross vehicle beam.

    13. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 482597 Size: SH
  13. Install the HVAC module to the cross vehicle beam with the retaining bolts.

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


    Object Number: 282301 Size: SH
  14. Install the center support bracket to the HVAC module.
  15. Secure the module to the bracket with the retaining bolts.

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

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

    18. Object Number: 486680 Size: SH
  18. Install the BCM bracket into position.
  19. Install the BCM bracket retaining bolts.

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


    Object Number: 486677 Size: SH
  20. Install the relay bracket into position.
  21. Install the relay bracket retaining bolts.

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


    Object Number: 637312 Size: SH
  22. Install the steering column support bracket.
  23. Install the steering column support bracket nuts.

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

  24. Install the brake pedal. Refer to Brake Pedal Replacement in Hydraulic Brakes.

    25. Object Number: 283722 Size: SH
  25. Install the right and left side air distributor duct.
  26. Install the screws to the right and left side air distributor duct.

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

  27. Install the passenger SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
  28. Install the instrument panel trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gages, and Console.