Installation Procedure

WARNING: This page is about a different car, the 2002 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.

Important: Align the defroster door assist spring to the HVAC module case.

Install the defroster door (1).

Fig 1: Defroster Door
Courtesy of GENERAL MOTORS CORP.
Install the air distribution case cover (2).
NOTE: Refer to FASTENER NOTICE .
Install the retaining screws (1) to the air distributor cover.
Tighten

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

Fig 2: Air Distributor Cover & Retaining Screws
Courtesy of GENERAL MOTORS CORP.
Connect the orange vacuum line to a hand vacuum pump (2).
Using the hand vacuum pump (2) open the recirculation actuator door.
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.
Connect the defroster actuator to the defroster door arm.
Position the defroster actuator on to the mounting slides of the HVAC module assembly.
Ensure that the lock tab locks the defroster actuator in place.

Fig 3: Defroster Actuator, Vacuum Lines & Hand Vacuum Pump
Courtesy of GENERAL MOTORS CORP.
Connect the vacuum lines to the defroster actuator.
Connect the vacuum line to the recirculation actuator.
Connect the mode actuator pushrod to the mode door lever.
Position the mode actuator on to the mounting slides of the HVAC module assembly.
Ensure that the lock tab locks the defroster actuator in place.
Connect the vacuum lines to the mode actuator.

Fig 4: Positioning Mode Actuator On Mounting Slides
Courtesy of GENERAL MOTORS CORP.
Install the cross vehicle beam to the vehicle.

Fig 5: Cross Vehicle Beam
Courtesy of GENERAL MOTORS CORP.
Install the bolts which secure the right cross vehicle beam to the hinge pillar.
Important: Do NOT tighten the bolts at this time.

Fig 6: Right Cross Vehicle Beam & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the bolts which secure the left cross vehicle beam to the hinge pillar.
Tighten

Tighten the bolts to 20 N.m (15 lb ft).

Fig 7: Left Cross Vehicle Beam & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the bolt (1) to the cross vehicle beam.
Tighten

Tighten the bolts to 20 N.m (15 lb ft).

Fig 8: Cross Vehicle Beam & Bolt
Courtesy of GENERAL MOTORS CORP.
Install the bolts to the upper support brackets of the HVAC module.
Tighten

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

Fig 9: HVAC Module Upper Support Bracket & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the HVAC module center support bracket.
Install the bolts to the center support bracket of the HVAC module.
Tighten

Tighten the bolts to 10 N.m (89 lb in).
Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.

Fig 10: HVAC Module Center Support Bracket & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the BCM bracket and bolts.
Tighten

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

Fig 11: BCM Bracket & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the fuse block to the holder.
Install the two screws below the fuse block that hold the main wire harness connector to the cross car beam.

Fig 12: Fuse Block
Courtesy of GENERAL MOTORS CORP.
Install the support bracket and bolts for the steering column.
Tighten

Tighten the bolts to 50 N.m (37 lb ft).
Install the brake pedal. Refer to BRAKE PEDAL ASSEMBLY .
Install the right and left side air distribution ducts.

Fig 13: Steering Column Support Bracket & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the right and left side air distribution duct bolts.
Tighten

Tighten the bolts to 1.5 N.m (13 lb in).
Install the passenger side SIR inflator module. Refer to REMOVAL & INSTALLATION (PASSENGER-SIDE) .
Install the IP trim pad. Refer to TRIM PAD REPLACEMENT -- IP .
Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .

Fig 14: Right & Left Air Distribution Ducts & Bolts
Courtesy of GENERAL MOTORS CORP.