GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Center Connector Duct Replacement

Removal Procedure

    Object Number: 896493 Size: SH
  1. Disable the SIR. Refer to Disabling the SIR System in SIR.
  2. Gently pull on the left and right side console extensions to remove the extensions.

    3. Object Number: 896945 Size: SH
  3. Power Window Vehicles Only: Using a small flat-blade tool, gently pry upward on the rear portion of the power window switch to partially disengage the switch from the console.
  4. Disconnect the power window switch harness from the switch and remove the power window switch.

    5. Object Number: 896592 Size: SH
  5. Disengage the console park brake boot by squeezing the boot in while pulling upward.
  6. Lift the park brake boot over the park brake assembly.

    7. Object Number: 896503 Size: SH
  7. Remove the front console tray by pulling upward on the tray assembly.
  8. Disconnect the console wiring harness from the main body harness.

    9. Object Number: 893814 Size: SH
  9. Automatic Transaxle Vehicles Only: Pull up on the PRNDL cover to disengage the cover.

    10. Object Number: 895322 Size: SH
  10. 5-Speed Transaxle Vehicles Only: Pull up on the shifter boot to disengage the boot.

    11. Object Number: 896495 Size: SH
  11. Move the front seats to the forward most position and remove the console rear fasteners.
  12. Move the front seats to the rearward most position and remove the console front fasteners.
  13. Gently lift the console up and over the shifter or PRNDL cover and remove the console assembly.

    14. Object Number: 896698 Size: SH
  14. Remove the I/P bracket.

    15. Object Number: 892666 Size: SH
  15. Remove the connector duct retaining screw.
  16. Pull the connector duct downward and then rearward to remove the connector duct from the HVAC module.
  17. Enable the SIR. Refer to Enabling the SIR System in SIR.

Installation Procedure

    Object Number: 892666 Size: SH
  1. Disable the SIR. Refer to Disabling the SIR System in SIR.
  2. Push the connector duct adapters completely up onto the main duct.
  3. Install the connector duct onto the HVAC module.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the connector duct to HVAC module screw.

    5. Tighten
    Tighten the HVAC center duct-to-HVAC module fastener to 1.0 N·m (9 lb in).

  5. Pull both legs of the connector duct down to seal against the left and right rear seat heater ducts.

    6. Object Number: 896698 Size: SH
  6. Install the I/P bracket.

    7. Tighten
    Tighten the I/P bracket nuts to 20 N·m (15 lb ft).


    Object Number: 896495 Size: SH
  7. Position the console into the vehicle. Route the shifter/PRNDL boot through the console opening.
  8. Install the console front fasteners.

    9. Tighten
    Tighten the console fasteners to 2.2 N·m (22 lb in).

  9. Move the front seats forward and install the console rear fasteners.

    10. Tighten
    Tighten the console fasteners to 2.2 N·m (22 lb in).


    Object Number: 893814 Size: SH
  10. Automatic Transaxle Vehicles Only: Snap the PRNDL cover into the console opening.

    11. Object Number: 895322 Size: SH
  11. 5-Speed Transaxle Vehicles Only: Snap the shifter boot into the console opening.
  12. Connect the console wiring harness to main body harness.

    13. Object Number: 896503 Size: SH
  13. Snap the console front tray into the console.

    14. Object Number: 896945 Size: SH
  14. Power Window Vehicles Only: Connect the power window harness to the power window switch and snap the switch into place.

    15. Object Number: 896592 Size: SH
  15. Snap the park brake boot into place.

    16. Object Number: 896493 Size: SH
  16. Install the console extensions.
  17. Enable the SIR. Refer to Enabling the SIR System in SIR.