GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2003 🢒 Grand Prix 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Defroster Air Outlet Replacement

Removal Procedure
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the instrument panel (I/P) trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gages, and Console.
  3. Remove the passenger side SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.

    4. Object Number: 573444 Size: SH
  4. Remove the screw from the center air duct.
  5. Remove the center air duct.

    6. Object Number: 283722 Size: SH
  6. Remove the screws from the side air ducts.
  7. Remove the side air ducts.

    8. Object Number: 813398 Size: SH
  8. Unclip the fuse block and position aside.
  9. Remove the 2 screws that hold the wire harness connector to the cross car beam under the fuse box.
  10. Remove the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  11. Remove the bolts for the steering column support bracket and remove the bracket.

    12. Object Number: 486680 Size: SH
  12. Remove the retaining bolts and position the BCM bracket aside.
  13. Release the wiring harness retaining clips from the cross vehicle beam and position the I/P wiring harness out of the way.

    14. Object Number: 282301 Size: SH
  14. Remove the retaining bolts from the center support bracket of the HVAC module.
  15. Remove the center support bracket of the HVAC module .

    16. Object Number: 482597 Size: SH
  16. Remove the retaining bolts from the upper support brackets of the HVAC module.

    17. Object Number: 482587 Size: SH
  17. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.

    18. Object Number: 482588 Size: SH
  18. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.

    19. Object Number: 811571 Size: SH
  19. Remove the bolt (1) from the cross vehicle beam.
  20. Remove the cross vehicle beam from the vehicle.

    21. Object Number: 176880 Size: SH
  21. Remove the screws and the defroster air distribution duct.

Installation Procedure

    Object Number: 176880 Size: SH
  1. Install the defroster air distribution duct.

    2. 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.

  2. Install the mounting screws.

    3. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).


    Object Number: 482600 Size: SH
  3. Install the cross vehicle beam to the vehicle.

    4. Object Number: 482588 Size: SH

    Important: Do NOT tighten the bolts at this time.

  4. Install the bolts which secure the right cross vehicle beam to the hinge pillar.

    5. Object Number: 482587 Size: SH
  5. Install the bolts which secure the left cross vehicle beam to the hinge pillar.

    6. Tighten
    Tighten the bolts to 20 N·m (15 lb ft).


    Object Number: 811571 Size: SH
  6. Install the bolt (1) to the cross vehicle beam.

    7. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 482597 Size: SH
  7. Install the upper support bracket bolts for the HVAC module.

    8. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 282301 Size: SH
  8. Install the HVAC module center support bracket.
  9. Install the bolts to the center support bracket of the HVAC module.

    10. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  10. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.

    11. Object Number: 486680 Size: SH
  11. Install the BCM bracket and the retaining bolts.

    12. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 813398 Size: SH
  12. Install the fuse block to the holder.
  13. Install the 2 screws below the fuse block that hold the main wire harness connector to the cross car beam.

    14. Object Number: 637312 Size: SH
  14. Install the support bracket and bolts for the steering column.

    15. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  15. Install the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  16. Install the passenger side SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.

    17. Object Number: 573444 Size: SH
  17. Install the center air distribution duct.
  18. Install the mounting screw.

    19. Tighten
    Tighten the screw to 1.5 N·m (13 lb in).


    Object Number: 283722 Size: SH
  19. Install the side air distribution ducts.
  20. Install the mounting screws.

    21. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  21. Install the I/P trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gauges, and Console.
  22. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.