GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 RELAY 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Recirculation Door Replacement

Removal Procedure

    Object Number: 1548560 Size: SH
  1. Remove the instrument panel (I/P) carrier. Refer to Instrument Panel Carrier Replacement .
  2. Disconnect the evaporator temperature sensor electrical connector (1).
  3. Remove the evaporator temperature sensor electrical connector (2) from the case.

    4. Object Number: 1547638 Size: SH
  4. Open the HVAC passenger compartment air filter access door.

    5. Object Number: 1547640 Size: SH
  5. Remove the HVAC passenger compartment air filters.

    6. Object Number: 1548559 Size: SH
  6. Disconnect the recirculation actuator electrical connector (1).

    7. Object Number: 1548546 Size: SH
  7. Remove the air inlet housing bolts/screws.

    8. Object Number: 1548550 Size: SH
  8. Remove the air inlet housing.

    9. Object Number: 1548539 Size: SH
  9. Remove the air inlet case bolts/screws (2).
  10. Separate the air inlet case halves.
  11. Remove the recirculation door (4).

Installation Procedure

    Object Number: 1548539 Size: SH
  1. Install the recirculation door (4).
  2. Align and install the left case to the right case.

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

  3. Install the air inlet case bolts/screws (2).

    4. Tighten
    Tighten the bolts/screws to 1.2 N·m (11 lb in).


    Object Number: 1548550 Size: SH
  4. Install the air inlet housing.

    5. Object Number: 1548546 Size: SH
  5. Install the air inlet housing bolts/screws.

    6. Tighten
    Tighten the bolts/screws to 1.2 N·m (11 lb in).


    Object Number: 1548559 Size: SH
  6. Connect the recirculation actuator electrical connector (1).

    7. Object Number: 1547640 Size: SH
  7. Install the HVAC passenger compartment air filters.

    8. Object Number: 1547638 Size: SH
  8. Close the HVAC passenger compartment air filter access door.
  9. Install the I/P carrier. Refer to Instrument Panel Carrier Replacement .
  10. Re-calibrate the actuators. Refer to Actuator Recalibration .