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Home >> Chevrolet >> 2002 >> Impala LS >> Repair and Diagnosis >> External Pages >> Different car >> Section 586 (HVAC Systems - Automatic) >> Repair Instructions >> Mode Door Replacement >> Installation Procedure

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 mode door assist spring to the HVAC module assembly case.
  1. Install the mode door (2).
  2. Install a new air distribution case seal.
    3. Fig 2: Air Distribution Case Cover & Retaining Screws
    GM607130Courtesy of GENERAL MOTORS CORP.
  3. Install the air distribution case cover (2).
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the retaining screws (1) to the air distributor cover.

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

    5. Fig 3: Connecting Mode Actuator Pushrod To Mode Door Lever
    GM295292Courtesy of GENERAL MOTORS CORP.
  5. Connect the mode actuator pushrod to the mode door lever.
  6. Position the mode actuator on to the mounting slides of the HVAC module assembly.
  7. Ensure that the lock tab locks the defroster actuator in place.
  8. Connect the vacuum lines to the mode actuator.
    9. Fig 4: Cross Vehicle Beam
    GM558194Courtesy of GENERAL MOTORS CORP.
  9. Install the cross vehicle beam to the vehicle.
    10. Fig 5: Cross Vehicle Beam & Bolts
    GM812572Courtesy of GENERAL MOTORS CORP.
  10. Install the bolts to the right and left side of the cross vehicle beam.
  11. 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).

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

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

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

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

  18. Reposition the IP wiring harness on to the cross vehicle beam and secure the retaining clips.
  19. 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).

  20. Install the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  21. Connect all disconnected ground wires.
  22. Reposition the body control module in place.
  23. Install the left side fuse block to the cross vehicle beam.
    24. Fig 8: Right Air Distribution Duct & Retaining Bolts
    GM507699Courtesy of GENERAL MOTORS CORP.
  24. Install the right air duct to the cross vehicle beam.
  25. Install the right air duct bolts.

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

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

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

  28. Install the panel air duct bolts.

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

  29. Install the steering column. Refer to Steering Column Replacement in Steering Wheel and Column.
  30. Install the IP 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.
  31. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
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