GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2001 🢒 Aztek - FWD 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Mode Door Replacement

Removal Procedure

    Important: The defroster door must be closed to allow clearance during defroster duct removal.

  1. Set the HVAC controls in the vent setting to close the defroster door.
  2. Remove the cross vehicle beam. Refer to Instrument Panel Tie Bar Replacement in Instrument Panel, Gages and Console.

    3. Important: Count the number of threads showing from the tip of the mode actuator push rod to the end of the retainer clip.


    Object Number: 828359 Size: SH
  3. Open the mode actuator push rod retainer clip (1) with a small flat bladed screwdriver.
  4. Disconnect the mode actuator push rod (2) from the retainer clip (1).

    5. Object Number: 828096 Size: SH
  5. Remove the left HVAC module mounting bracket from the HVAC module assembly.
  6. Remove the right HVAC module mounting bracket from the HVAC module assembly.

    7. Object Number: 860400 Size: SH
  7. Disconnect the secondary defroster door lever from the secondary defroster door.

    8. Object Number: 860412 Size: SH
  8. Disconnect the defroster door spring (1) from the air distribution cover.

    9. Object Number: 860404 Size: SH
  9. Remove the air distribution cover screws.
  10. Remove the air distribution cover.

    11. Object Number: 860442 Size: SH
  11. Remove the mode door from the HVAC module assembly.
  12. Disconnect and remove the left hand and right hand mode door levers from the mode door.

Installation Procedure

    Object Number: 860442 Size: SH
  1. Connect the left hand and right hand mode door levers to the mode door.

    2. Important: Align the slot in the left hand mode door lever with the mode door main lever pin. Align the pin on the right hand mode door lever with the slot in the secondary mode door.

  2. Install the mode door.

    3. Object Number: 860404 Size: SH
  3. Install the air distribution cover.

    4. 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.

  4. Install the air distribution cover screws.

    5. Tighten
    Tighten the screws to 0.9 N·m (8 lb in).


    Object Number: 860412 Size: SH
  5. Connect the defroster door spring (1) to the air distribution cover.

    6. Important: Align the slot on the secondary defroster door lever with the pin on the mode door main lever.


    Object Number: 860400 Size: SH
  6. Connect the secondary defroster door lever to the secondary defroster door.

    7. Object Number: 828096 Size: SH
  7. Install the right HVAC module mounting bracket to the HVAC module assembly.
  8. Install the right HVAC module mounting bracket screws.

    9. Tighten
    Tighten the screws to 1.8 N·m (16 lb in).

  9. Install the left HVAC module mounting bracket to the HVAC module assembly.
  10. Install the left HVAC module mounting bracket screws.

    11. Tighten
    Tighten the screws to 1.8 N·m (16 lb in).

    Important: Align the counted number of threads on the mode actuator push rod (2) with the tip of the retainer clip (1).


    Object Number: 828359 Size: SH
  11. Connect the mode actuator push rod (2) to the retainer clip (1).
  12. Close the push rod retainer clip (1).
  13. Install the cross vehicle beam. Refer to Instrument Panel Tie Bar Replacement in Instrument Panel, Gages and Console.