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

Removal Procedure

    Object Number: 1548538 Size: SH
  1. Remove the heater core cover. Refer to Heater Core Cover Replacement .
  2. Remove the mode actuator bolts/screws (1).
  3. Remove the mode actuator (2).
  4. Remove the mode actuator lever cover bolts/screws (3).
  5. Remove the mode actuator lever cover (4).
  6. Remove the mode actuator cam (5).
  7. Remove the mode actuator lever (6).
  8. Remove the secondary mode door (7).

Installation Procedure

    Object Number: 1548538 Size: SH
  1. Install the secondary mode door (7).

    2. Object Number: 1548537 Size: SH
  2. Install the mode actuator levers (4, 6). The pin on lever (4) should be seen through the opening in lever (6).
  3. Install the mode actuator cam (1). The pin on lever (6) should be seen through this opening (5) in the cam.

    4. Object Number: 1548538 Size: SH
  4. Install the mode actuator lever cover (4).

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

  5. Install the mode actuator lever cover bolts/screws (3).

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

  6. Install the mode actuator (2).
  7. Install the mode actuator bolts/screws (1).

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

  8. Install the heater core cover. Refer to Heater Core Cover Replacement .
  9. Re-calibrate the actuators. Refer to Actuator Recalibration .