GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 2003 🢒 Rendezvous - FWD 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Defroster Door Replacement

Removal Procedure

    Important: The defroster door must be closed to allow clearance during defroster duct removal.

  1. Set the HVAC controls in the vent setting to close the defroster door.
  2. Remove the I/P carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages and Console.

    3. Object Number: 828096 Size: SH
  3. Remove the left HVAC module mounting bracket from the HVAC module assembly.
  4. Remove the right HVAC module mounting bracket from the HVAC module assembly.

    5. Object Number: 860400 Size: SH
  5. Disconnect the secondary defroster door lever from the secondary defroster door.

    6. Object Number: 860412 Size: SH
  6. Disconnect the defroster door spring (1) from the air distribution cover.
  7. Disconnect and remove the defroster door lever (2) and defroster door spring (1) from the defroster door.

    8. Object Number: 860404 Size: SH
  8. Remove the air distribution cover screws.
  9. Remove the air distribution cover.

    10. Object Number: 860406 Size: SH
  10. Remove the defroster door.

Installation Procedure

    Object Number: 860406 Size: SH
  1. Install the defroster door.

    2. Object Number: 860404 Size: SH
  2. Install the air distribution cover.

    3. 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.

  3. Install the air distribution cover screws.

    4. Tighten
    Tighten the screws to 0.9 N·m (8 lb in).

    Important: Align the slot on the defroster door lever with the pin on the mode door main lever.


    Object Number: 860412 Size: SH
  4. Connect the defroster door lever (2) and the defroster door spring (1) to the defroster door.
  5. Connect the defroster door spring (1) to the air distribution cover.

    6. Important: Align the slot on the secondary defroster door lever with the pin on the mode door main lever.


    Object Number: 860400 Size: SH
  6. Connect the secondary defroster door lever to the secondary defroster door.

    7. Object Number: 828096 Size: SH
  7. Install the right HVAC module mounting bracket to the HVAC module assembly.
  8. Install the right HVAC module mounting bracket screws.

    9. Tighten
    Tighten the screws to 1.8 N·m (16 lb in).

  9. Install the left HVAC module mounting bracket to the HVAC module assembly.
  10. Install the left HVAC module mounting bracket screws.

    11. Tighten
    Tighten the screws to 1.8 N·m (16 lb in).

  11. Install the I/P carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages and Console.