GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2003 🢒 Montana 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Recirculation Door Replacement

Removal Procedure
  1. Remove the instrument panel (I/P) carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages, and Console.
  2. Open the HVAC passenger compartment air filter access door.
  3. Remove the HVAC passenger compartment air filters.
  4. Disconnect the recirculation actuator electrical connector.

    5. Object Number: 825400 Size: SH
  5. Remove the top air inlet housing retaining screws.
  6. Remove the side air inlet housing retaining screws.
  7. Remove the air inlet housing from the HVAC module assembly.

    8. Object Number: 400648 Size: SH
  8. Remove the screws retaining the air inlet housing halves.
  9. Separate the air inlet housing halves.

    10. Object Number: 400651 Size: SH
  10. Remove the recirculation door from the air inlet housing.

Installation Procedure

    Object Number: 400651 Size: SH
  1. Install the recirculation door to the air inlet housing.

    2. Object Number: 400648 Size: SH
  2. Align the recirculation door with the other half of the air inlet housing.
  3. Connect the air inlet housing halves.

    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 screws retaining the air inlet housing halves.

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


    Object Number: 825400 Size: SH
  5. Install the air inlet housing to the HVAC module assembly.
  6. Install the air inlet housing screws.

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

  7. Connect the recirculation actuator electrical connector.
  8. Install the HVAC passenger compartment air filters.
  9. Close the HVAC passenger compartment air filter access door.
  10. Install the I/P carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gages, and Console.