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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1666 (Heating, Ventilation And Air Conditioning) >> Repair Instruction >> Defroster Door Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Buick Regal and 2003 Buick Century. 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 assembly case.
  1. Install the defroster door (1).
    Fig 1: View Of Defroster Door
    G01568773Courtesy of GENERAL MOTORS CORP.
  2. Connect the linkage between the defroster door and the vent door.
  3. Install a new air distribution case seal.
  4. Install the air distribution case cover (2).
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  5. Install the air distributor cover retaining screws (1).

    Tighten 

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

    Fig 2: Installing Air Distribution Case Cover & Retaining Screws
    G01568774Courtesy 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.
    Fig 3: Connecting Vacuum Lines To Defroster Actuator
    G01568775Courtesy of GENERAL MOTORS CORP.
  12. Connect the vacuum lines to the defroster actuator.
  13. Connect the vacuum line to the recirculation actuator.
  14. Install the cross vehicle beam to the vehicle.
    Fig 4: View Of Cross Vehicle Beam To Vehicle
    G01568776Courtesy of GENERAL MOTORS CORP.
  15. Install the bolts which secure the right cross vehicle beam to the hinge pillar. Tighten the bolts finger tight.
    Fig 5: Identifying Bolts Which Secure Right Cross Vehicle Beam To Hinge Pillar
    G01568777Courtesy of GENERAL MOTORS CORP.
  16. Install the bolts which secure the left cross vehicle beam to the hinge pillar. Tighten the bolts finger tight.

    Tighten 

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

    Fig 6: Locating Bolts Which Secure Left Cross Vehicle Beam To Hinge Pillar
    G01568778Courtesy of GENERAL MOTORS CORP.
  17. Install the bolt (1) to the cross vehicle beam.

    Tighten 

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

    Fig 7: Installing Bolt To Cross Vehicle Beam
    G01568779Courtesy of GENERAL MOTORS CORP.
  18. Install the bolts to the upper support brackets of the HVAC module.

    Tighten 

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

    Fig 8: Installing Bolts To Upper Support Brackets Of HVAC Module
    G01568780Courtesy of GENERAL MOTORS CORP.
  19. Install the center support bracket to the HVAC module.
  20. Install the bolts to the center support bracket of the HVAC module.

    Tighten 

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

  21. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.
  22. Install the two screws below the fuse block that hold the main wire harness connector to the cross vehicle beam.
    Fig 9: Installing Center Support Bracket & Mounting Bolts To HVAC Module
    G01568781Courtesy of GENERAL MOTORS CORP.
  23. Install the BCM bracket and the bolts.

    Tighten 

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

    Fig 10: Installing BCM Bracket & Bolts
    G01568782Courtesy of GENERAL MOTORS CORP.
  24. Install the relay bracket and the bolts.

    Tighten 

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

    Fig 11: Installing Relay Bracket & Bolts
    G01568783Courtesy of GENERAL MOTORS CORP.
  25. Install the right and left side air distribution duct bolts.

    Tighten 

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

    Fig 12: Installing Right & Left Side Air Distribution Duct Bolts
    G01568784Courtesy of GENERAL MOTORS CORP.
  26. Install the steering column support bracket to the cross vehicle beam.
  27. Install the nuts and bolts to the steering column support bracket.

    Tighten 

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

    Fig 13: Installing Nuts & Bolts To Steering Column Support Bracket
    G01568785Courtesy of GENERAL MOTORS CORP.
  28. Install the brake pedal. Refer to BRAKE PEDAL ASSEMBLY in Disc & Drum.
  29. Connect all disconnected ground wires.
  30. Install the passenger side SIR inflator module. Refer to AIR BAG MODULES
  31. Install the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT -- INSTRUMENT PANEL (I/P) in Instrument Panel, Gages and Console.
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