GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Uplander Ext. 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Secondary Mode Door Replacement

Secondary Mode Door Replacement Dual Zone

Removal Procedure
  1. Remove the heater core cover. Refer to Heater Core Cover Replacement .
  2. Remove the right hand air temperature actuator. Refer to Temperature Valve Actuator Replacement - Right Side .

    3. Object Number: 868233 Size: SH
  3. Remove the right hand air temperature mounting bracket screws.
  4. Remove the right hand air temperature mounting bracket.

    5. Object Number: 867765 Size: SH
  5. Disconnect and remove the right hand mode door lever from the mode door.

    6. Object Number: 867766 Size: SH
  6. Disconnect and remove the secondary mode door lever from the secondary mode door.

    7. Object Number: 868074 Size: SH
  7. Remove the secondary mode door from the HVAC module.

Installation Procedure

    Object Number: 868074 Size: SH
  1. Install the secondary mode door.

    2. Object Number: 867766 Size: SH
  2. Connect the secondary mode door lever to the secondary mode door.

    3. Object Number: 867765 Size: SH

    Note: Align the pin on the right hand mode door lever with the slot on the secondary mode door lever.

  3. Connect the right hand mode door lever to the mode door.

    4. Object Number: 868233 Size: SH
  4. Install the right hand air temperature mounting bracket.

    5. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the right hand air temperature mounting bracket screws and tighten to 0.9 N·m (8 lb in) .
  6. Install the right hand air temperature actuator. Refer to Temperature Valve Actuator Replacement - Right Side .
  7. Install the heater core cover. Refer to Heater Core Cover Replacement .

Secondary Mode Door Replacement Single Zone

Removal Procedure

    Object Number: 1548538 Size: SH
  1. Remove the heater core cover. Refer to Heater Core Cover Replacement .
  2. Remove the mode actuator bolts/screws (1).
  3. Remove the mode actuator (2).
  4. Remove the mode actuator lever cover bolts/screws (3).
  5. Remove the mode actuator lever cover (4).
  6. Remove the mode actuator cam (5).
  7. Remove the mode actuator lever (6).
  8. Remove the secondary mode door (7).

Installation Procedure

    Object Number: 1548538 Size: SH
  1. Install the secondary mode door (7).

    2. Object Number: 1548537 Size: SH
  2. Install the mode actuator levers (4, 6). The pin on lever (4) should be seen through the opening in lever (6).
  3. Install the mode actuator cam (1). The pin on lever (6) should be seen through this opening (5) in the cam.

    4. Object Number: 1548538 Size: SH
  4. Install the mode actuator lever cover (4).

    5. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the mode actuator lever cover bolts/screws (3) and tighten to 1.2 N·m (11 lb in) .
  6. Install the mode actuator (2).
  7. Install the mode actuator bolts/screws (1) and tighten to 1.2 N·m (11 lb in) .
  8. Install the heater core cover. Refer to Heater Core Cover Replacement .