GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2003 🢒 Grand Prix 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Mode Door 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: 283722 Size: SH
  4. Remove the screws from the right and left side air distribution ducts.
  5. Remove the air distribution ducts.

    6. Object Number: 813398 Size: SH
  6. Unclip the fuse block and position aside.
  7. Remove the 2 screws below the fuse block that hold the main wire harness connector to the cross car beam.
  8. Remove the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  9. Disconnect any ground wires, as necessary.
  10. Remove the nuts and bolts from the steering column support bracket.
  11. Remove the steering column support bracket from the cross vehicle beam.

    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 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: 295281 Size: SH
  21. Disconnect the vacuum lines from the mode actuator.
  22. Lift the lock tab up (1) to remove the actuator.
  23. Remove the mode actuator off the slides of the HVAC module assembly.
  24. Disconnect the actuator pushrod from the mode door lever and remove the actuator.

    25. Object Number: 607130 Size: SH
  25. Remove the retaining screws (1) from the air distribution case cover.
  26. Remove the air distribution case cover  (2).

    27. Object Number: 607136 Size: SH
  27. Remove the mode door (2).

Installation Procedure

    Object Number: 607136 Size: SH

    Important: Align the mode door assist spring to the HVAC module case.

  1. Install the mode door (2).

    2. Object Number: 607130 Size: SH
  2. Install the air distribution case cover (2).

    3. 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.

  3. Install the retaining screws (1) to the air distributor cover.

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


    Object Number: 295292 Size: SH
  4. Connect the mode actuator pushrod to the mode door lever.
  5. Position the mode actuator on to the mounting slides of the HVAC module assembly.
  6. Ensure that the lock tab locks the defroster actuator in place.
  7. Connect the vacuum lines to the mode actuator.

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

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

    10. Important: Do NOT tighten the bolts at this time.


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

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


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

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


    Object Number: 482597 Size: SH
  12. Install the retaining bolts to the upper support brackets of the HVAC module.

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


    Object Number: 282301 Size: SH
  13. Install the HVAC module center support bracket.
  14. Install the retaining bolts to the center support bracket of the HVAC module.

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

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

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

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


    Object Number: 813398 Size: SH
  17. Install the fuse block to the holder.
  18. Install the 2 screws below the fuse block that hold the main wire harness connector to the cross car beam.
  19. Install the steering column support bracket to the cross vehicle beam.

    20. Object Number: 637312 Size: SH
  20. Install the steering column support bracket nuts and bolts.

    21. Tighten
    Tighten the nuts and bolts to 50 N·m (37 lb ft).

  21. Install the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  22. Connect all disconnected ground wires.
  23. Install the passenger side SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.

    24. Object Number: 283722 Size: SH
  24. Install the right and left side air distribution ducts.
  25. Install the right and left side air distribution duct bolts.

    26. Tighten
    Tighten the bolts to 1.5 N·m (13 lb in).

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