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Installation Procedure

WARNING: This page is about a different car, the 2003 Chevrolet Monte Carlo and 2003 Chevrolet Impala. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Door Assembly
    GM607136Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Align the defroster door assist spring to the HVAC module assembly case.
  1. Install the defroster door (1).
  2. Connect the linkage between the defroster door and the vent door.
  3. Install a new air distribution case seal.
    4. Fig 2: Air Distribution Case Cover & Retaining Screws
    GM607130Courtesy of GENERAL MOTORS CORP.
  4. Install the air distribution case cover (2).
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the retaining screws (1) to the air distributor cover.

    Tighten:  Tighten the screws to 1.5 N.m (13 lb in).

    6. Fig 3: View Of Defroster Actuator & Vacuum Pump
    GM708587Courtesy of GENERAL MOTORS CORP.
  6. Connect the orange vacuum line to a hand vacuum pump (2).
  7. Using the hand vacuum pump (2) open the recirculation actuator door.
  8. Rotate the defroster actuator to the right and up into the opening between the back of the dash and the opening into the HVAC module. The opening which results when the recirculation actuator door is in the full open position.
  9. Connect the defroster actuator to the defroster door arm.
  10. Position the defroster actuator on to the mounting slides of the HVAC module assembly.
  11. Ensure that the lock tab locks the defroster actuator in place.
  12. Connect the vacuum lines to the defroster actuator.
  13. Connect the vacuum line to the recirculation actuator.
    14. Fig 4: Cross Vehicle Beam
    GM558194Courtesy of GENERAL MOTORS CORP.
  14. Install the cross vehicle beam to the vehicle.
    15. Fig 5: Cross Vehicle Beam & Bolts
    GM812572Courtesy of GENERAL MOTORS CORP.
  15. Install the bolts to the right and left side of the cross vehicle beam.
  16. Tighten the bolts to the right and left side of the cross vehicle beam in sequence.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    17. Fig 6: HVAC Module Upper Support
    GM558113Courtesy of GENERAL MOTORS CORP.
  17. Install the bracket bolts to the HVAC module upper support.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

  18. Install the passenger knee bolster bracket. Refer to Knee Bolster Bracket Replacement - Right in Instrument Panel, Gages, and Console.
    19. Fig 7: HVAC Module Center Support & Bolts
    GM558111Courtesy of GENERAL MOTORS CORP.
  19. Install the bracket to the HVAC module center support.
  20. Reposition the vacuum harness to the original position.
  21. Install the bracket bolts to the HVAC module center support.
  22. Tighten the bracket bolts in sequence as shown.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

  23. Reposition the IP wiring harness to the cross vehicle beam and secure the retaining clips.
  24. Install the 3 bolts through the brake pedal bracket to the cross vehicle beam.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

  25. Install the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  26. Connect all disconnected ground wires.
  27. Reposition the body control module in place.
  28. Install the fuse blocks to the cross vehicle beam.
    29. Fig 8: Right Air Distribution Duct & Retaining Bolts
    GM507699Courtesy of GENERAL MOTORS CORP.
  29. Install the right air duct to the cross vehicle beam.
  30. Install the right air duct bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    31. Fig 9: Panel Air Duct, Retaining Screw & Retaining Bolts
    GM812951Courtesy of GENERAL MOTORS CORP.
  31. Install the panel air duct to the cross vehicle beam.
  32. Install the panel air duct screw (1).

    Tighten:  Tighten the bolts to 1.8 N.m (16 lb in).

  33. Install the panel air duct bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

  34. Install the steering column. Refer to Steering Column Replacement in Steering Wheel and Column.
  35. Install the lower trim panel. Refer to Instrument Panel (I/P) Trim Panel Replacement - Lower (Impala) or Instrument Panel (I/P) Trim Panel Replacement - Lower (Monte Carlo) in Instrument Panel, Gages, and Console.
  36. Connect the battery negative cable.
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