GM Service Manual Online
For 1990-2009 cars only

Mode Door Replacement - Upper Visteon

Removal Procedure

  1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .

  2. Object Number: 826791  Size: SH
  3. Disconnect the electrical connector (3) from the mode actuator (4).
  4. Remove the screws from the mode actuator (4).
  5. Remove the mode actuator (4) from the HVAC module assembly (1).
  6. Remove the wiring harness from the air distribution housing (1).

  7. Object Number: 826798  Size: SH
  8. Remove the screws from the air distribution housing (1).
  9. Remove the air distribution housing (1) from the HVAC module assembly (2).

  10. Object Number: 826686  Size: SH
  11. Remove the screws from the air distribution housing (1).
  12. Separate the air distribution housing halves.

  13. Object Number: 826697  Size: SH
  14. Remove the lever from the upper mode door (4).
  15. Remove the lever from the defrost door (2).
  16. Remove the door assembly (3) from the left air distribution housing (1).
  17. Remove the mode door (4) from the door assembly (3).

Installation Procedure


    Object Number: 826697  Size: SH
  1. Install the mode door (4) to the door assembly (3).
  2. Install the door assembly (3) to the left air distribution housing (1).
  3. Install the lever to the defrost door (2).
  4. Install the lever to the upper mode door (4).

  5. Object Number: 826686  Size: SH
  6. Install the air distribution housing halves.
  7. 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 screws to the air distribution housing (1).
  9. Tighten
    Tighten the screws to 2 N·m (18 lb in).


    Object Number: 826798  Size: SH
  10. Install the air distribution housing (1) to the HVAC module assembly (2).
  11. Install the screws to the air distribution housing (1).
  12. Tighten
    Tighten the screws to 2 N·m (18 lb in).

  13. Install the wiring harness to the air distribution housing (1).

  14. Object Number: 826791  Size: SH
  15. Connect the electrical connector (3) to the mode actuator (4).
  16. Install the mode actuator (4) to the HVAC module assembly (1).
  17. Install the screws to the mode actuator (4).
  18. Tighten
    Tighten the screws to 2 N·m (18 lb in).

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

Mode Door Replacement - Upper Delphi

Removal Procedure

Important: The upper mode door (6) is serviced with the upper HVAC module case (3).


    Object Number: 899652  Size: SH
  1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
  2. Disconnect the electrical connector (3) from the mode actuator (4).
  3. Remove the screws from the mode actuator (4).
  4. Remove the mode actuator (4) from the HVAC module assembly (1).
  5. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer.

  6. Object Number: 962571  Size: SH
  7. If equipped remove the HVAC module assembly screws.
  8. Separate the HVAC module assembly.
  9. Remove the lever (7) from the upper mode door/upper HVAC module case (6).

Installation Procedure


    Object Number: 962571  Size: SH
  1. Install the lever (7) to the upper mode door/upper HVAC module case (6).
  2. Install the HVAC module assembly halves.
  3. Notice: Refer to Fastener Notice in the Preface section.

    Important: For every heat stake removed ensure that you install a screw.

  4. Install the screws to the HVAC module assembly.
  5. Tighten
    Tighten the screws to 1.6 N·m (14 lb in).

  6. Install the mode actuator to the HVAC module assembly.
  7. Install the screws to the mode actuator.
  8. Tighten
    Tighten the screws to 1.6 N·m (14 lb in).

  9. Connect the electrical connector to the mode actuator.
  10. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement .