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

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

    3. Object Number: 864405 Size: SH
  3. Remove the cam, the cable, and the screws.

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

    5. Object Number: 869004 Size: SH
  5. Remove the actuator and 2 screws from the upper case.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 869004 Size: SH
  1. Install the actuator and 2 screws to the upper case.

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


    Object Number: 868880 Size: SH
  2. Install the upper case assembly.

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


    Object Number: 864405 Size: SH
  3. Install the cam, the cable and the screw.

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

  4. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement .