Condensation Forming on I/P Top Cover and I/P Accessory Bezel (Re-align/Re-connect Center Panel Duct)

Customers may comment that condensation forms on the Instrument Panel (I/P) top cover and/or the I/P accessory bezel during times of high humidity. In some cases, condensation may also collect inside the CD player and cause the CD player to become inoperative.

The center I/P Air Outlet Duct assembly may not be aligned with the I/P accessory bezel outlet. If the duct is not properly aligned/connected, cool dehumidified air may leak into an area around I/P components that have warm moist air, causing condensation to form in various places.

Realign/reconnect the duct assembly to the bezel outlet. Inspect to make sure the I/P wire harness is not interfering with alignment.

1. Using a bright light, inspect the center duct to accessory bezel connection by viewing through the I/P center air outlet deflector. If the duct is not connected/aligned, there will be a gap between the duct foam and the accessory bezel outlet.
2. If the duct is properly connected/aligned, try to duplicate condition and/or interview the customer for more details. Refer to the 2002-2003 Saturn VUE HVAC Service Manual, Vol. I for further diagnostics.



3. To re-connect/re-align duct to accessory bezel outlet, remove air outlet deflector. To remove deflectors, use a protected (to prevent damage) flat bladed tool to gently pry up at the outboard edge to remove.
4. Inspect to make sure I/P wire harness is not interfering with alignment. If I/P wire harness is interfering with alignment, move I/P wire harness out of the way.



5. Align duct to accessory bezel.



6. Install center air outlet deflector by placing round opening on inboard (straight) side of the deflector over pin.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for D1442 (Deflector/Outlet, Air, Right Center -- R&R or Replace). An "Add Time" is provided to remove left center deflector and adjust air outlet duct.