Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Oldsmobile Silhouette, and 2003 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.

Important: The defroster door must be closed to allow clearance during defroster duct removal.

Set the HVAC controls in the vent setting to close the defroster door.
Remove the IP carrier. Refer to INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT in Instrument Panel, Gages and Console.
Important: Count the number of threads showing from the tip of the mode actuator push rod to the end of the retainer clip.
Open the mode actuator push rod retainer clip (1) with a small flat bladed screwdriver.
Disconnect the mode actuator push rod (2) from the retainer clip (1).

Fig 1: Opening Mode Actuator Push Rod Retainer Clip
Courtesy of GENERAL MOTORS CORP.
Remove the left HVAC module mounting bracket from the HVAC module assembly.
Remove the right HVAC module mounting bracket from the HVAC module assembly.

Fig 2: Removing Left & Right HVAC Module Mounting Brackets
Courtesy of GENERAL MOTORS CORP.
Disconnect the secondary defroster door lever from the secondary defroster door.

Fig 3: Disconnecting Secondary Defroster Door Lever From Secondary Defroster Door
Courtesy of GENERAL MOTORS CORP.
Disconnect the defroster door spring (1) from the air distribution cover.

Fig 4: Disconnecting Defroster Door Spring From Air Distribution Cover
Courtesy of GENERAL MOTORS CORP.
Remove the air distribution cover screws.
Remove the air distribution cover.

Fig 5: Removing Air Distribution Cover Screws
Courtesy of GENERAL MOTORS CORP.
Remove the mode door from the HVAC module assembly.
Disconnect and remove the left hand and right hand mode door levers from the mode door.

Fig 6: Removing Mode Door From HVAC Module Assembly
Courtesy of GENERAL MOTORS CORP.