Removal 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.

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 I/P carrier. Refer to INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT .
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 1: Removing Procedure Defroster Door
Courtesy of GENERAL MOTORS CORP.
Disconnect the secondary defroster door lever from the secondary defroster door.

Fig 2: Disconnecting Secondary Defroster Door Lever
Courtesy of GENERAL MOTORS CORP.
Disconnect the defroster door spring (1) from the air distribution cover.
Disconnect and remove the defroster door lever (2) and defroster door spring (1) from the defroster door.

Fig 3: Disconnecting Defroster Door Spring
Courtesy of GENERAL MOTORS CORP.
Remove the air distribution cover screws.
Remove the air distribution cover.

Fig 4: Removing Air Distribution Cover Screws
Courtesy of GENERAL MOTORS CORP.
Remove the defroster door.

Fig 5: Removing Defroster Door
Courtesy of GENERAL MOTORS CORP.