GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 Sonoma Pickup - 4WD 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Defroster Door Replacement

Removal Procedure
  1. Remove the heater/vent module. Refer to Heater/Vent Module Replacement .

    2. Object Number: 696053 Size: SH
  2. Remove screws in order to separate the heater/vent module halves.

    3. Object Number: 687384 Size: SH
  3. Disconnect the actuator linkage from the door end.
  4. Disconnect the air temperature actuator electrical connector.
  5. Remove the air temperature actuator screws.
  6. Remove the air temperature actuator from the module.
  7. Remove the vacuum harness from the defrost actuator.
  8. Remove the defrost actuator rod retaining clip.
  9. Remove the acutator rod from the defrost door.
  10. Remove the defrost actuator from the module.
  11. Remove the vacuum harness from the mode actuator.
  12. Remove the mode actuator rod retaining clip.
  13. Remove the acutator rod from the mode door.
  14. Remove the mode actuator from the module.
  15. Remove the air temperature door.
  16. Remove the defrost door (2) from the lower module.

Installation Procedure

    Object Number: 687384 Size: SH
  1. Install the defrost door (2) to the lower module.
  2. Install the air temperature door.
  3. Install the mode actuator to the module.
  4. Install the mode actuator to the mode door.
  5. Install the actuator rod retaining clip.
  6. Connect the mode actuator vacuum harness.
  7. Install the air temperature actuator to the module.

    8. 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.

  8. Install the air temperature actuator screws.

    9. Tighten
    Tighten the screws to 1.9 N·m (17 lb in).

  9. Connect the air temperature actuator electrical connector.

    10. Object Number: 696053 Size: SH
  10. Install the screws to the heater/vent module halves.

    11. Tighten
    Tighten the screws to 4.5 N·m (40 lb in).

  11. Connect the actuator linkage to the door end.
  12. Install the heater/vent module. Refer to Heater/Vent Module Replacement .