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

    Object Number: 869004 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.

  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 .