Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.

Install the air temperature door.

Fig 1: Installing Air Temperature Door
Courtesy of GENERAL MOTORS CORP.

Important: Align the evaporator temperature sensor wires with the opening in the upper HVAC module case. Improper alignment will pinch and/or cut the sensor wires.
Align and install the upper module case to the lower module case.
Install the lower HVAC module screws.
Tighten

Tighten the screws to 0.9 N.m (8 lb in).

Fig 2: Installing Lower HVAC Module Screws
Courtesy of GENERAL MOTORS CORP.
Install the lower HVAC module retaining screw.
Install the heater core.
Install the heater core pipe retaining screw.
Tighten

Tighten the screw to 0.9 N.m (8 lb in).

Fig 3: Installing Heater Core
Courtesy of GENERAL MOTORS CORP.
Install the heater core cover.
Install the heater core cover screws.
Tighten

Tighten the screws to 0.9 N.m (8 lb in).

Fig 4: Installing Heater Core Cover
Courtesy of GENERAL MOTORS CORP.
Install the heater outlet duct.
Install the heater outlet duct screws.
Tighten

Tighten the screws to 0.9 N.m (8 lb in).

Fig 5: Installing Heater Outlet Duct Screws./caption>
Courtesy of GENERAL MOTORS CORP.
Install the HVAC module upper retaining screw.
Tighten

Tighten the screw to 0.9 N.m (8 lb in).
Install the right HVAC module mounting bracket.
Install the right HVAC module mounting bracket screws.
Tighten

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

Fig 6: Installing Right HVAC Module Mounting Bracket Screws
Courtesy of GENERAL MOTORS CORP.
Install the HVAC module assembly to dash panel sound barrier seal.

Fig 7: Installing HVAC Module Assembly To Dash Panel Sound Barrier Seal
Courtesy of GENERAL MOTORS CORP.
Install the air inlet housing.
Install the air inlet housing screws.
Tighten

Tighten the screws to 0.9 N.m (8 lb in).

Fig 8: Installing Air Inlet Housing Screws
Courtesy of GENERAL MOTORS CORP.

Important: Align the pin on the air temperature actuator with the slot in the temperature door lever.
Install the temperature door lever (1) to the temperature door.
Connect the temperature door lever spring (2) to the temperature door lever (1) and HVAC module case.
Install the temperature door lever bolt (3) to the HVAC module case.
Tighten

Tighten the bolt to 0.9 N.m (8 lb in).
Install the HVAC module assembly. Refer to HVAC MODULE ASSEMBLY REPLACEMENT .

Fig 9: Tightening Torque Of Door Lever Bolt
Courtesy of GENERAL MOTORS CORP.