GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Cavalier 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Air Temperature Door Replacement

Removal Procedure
  1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
  2. Remove the heat stakes and the screws from the upper case assembly.

    3. Object Number: 868880 Size: SH
  3. Remove the upper case assembly.

    4. Object Number: 864482 Size: SH
  4. Disconnect the air temperature cable from the temperature door.

    5. Object Number: 869019 Size: SH
  5. Remove the air temperature door from the HVAC module assembly. Complete the following steps:
    6. 5.1. Slide the door to the right.
    5.2. Pull down on the door in order to remove the link end of the door.

Installation Procedure

    Object Number: 869019 Size: SH
  1. Install the air temperature door to the HVAC module assembly. Complete the following steps:
    2. 1.1. Insert the link end of the door into the HVAC module assembly.
    1.2. Push up on the door into the HVAC module assembly in order to seat the door.

    Object Number: 864482 Size: SH
  2. Connect the air temperature cable to the air temperature door.

    3. Object Number: 868880 Size: SH

    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 upper case assembly and the screws.

    4. Tighten
    Tighten the screws to 1 N·m (9 lb in).

  4. Install the HVAC module assembly. Refer to Air Conditioning Evaporator Core Replacement .