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Removal 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.
  1. Disconnect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  2. Remove the instrument panel (IP) trim pad. Refer to TRIM PAD REPLACEMENT -- IP .
  3. Remove the passenger side SIR inflator module. Refer to REMOVAL & INSTALLATION (PASSENGER-SIDE) .
  4. Remove the screws from the right and left side air distribution ducts.
  5. Remove the air distribution ducts.
    Fig 1: Air Distribution Ducts & Screws
    G01672797Courtesy of GENERAL MOTORS CORP.
  6. Unclip the fuse block and position aside.
  7. Remove the two screws below the fuse block that hold the main wire harness connector to the cross car beam.
  8. Remove the brake pedal. Refer to BRAKE PEDAL ASSEMBLY .
  9. Remove the bolts from the steering column support bracket and remove the bracket.
    Fig 2: Fuse Block
    G01672798Courtesy of GENERAL MOTORS CORP.
  10. Remove the retaining bolts and position the BCM bracket aside.
  11. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness out of the way.
    Fig 3: BCM Bracket & Retaining Bolts
    G01672799Courtesy of GENERAL MOTORS CORP.
  12. Remove the retaining bolts from the center support bracket of the HVAC module.
  13. Remove the center support bracket of the HVAC module.
    Fig 4: HVAC Module Center Support Bracket & Retaining Bolts
    G01672800Courtesy of GENERAL MOTORS CORP.
  14. Remove the retaining bolts from the upper support brackets of the HVAC module.
    Fig 5: HVAC Module Upper Support Bracket & Retaining Bolts
    G01672801Courtesy of GENERAL MOTORS CORP.
  15. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.
    Fig 6: Left Cross Vehicle Beam & Bolts
    G01672802Courtesy of GENERAL MOTORS CORP.
  16. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.
    Fig 7: Right Cross Vehicle Beam & Bolts
    G01672803Courtesy of GENERAL MOTORS CORP.
  17. Remove the bolt (1) from the cross vehicle beam.
  18. Remove the cross vehicle beam from the vehicle.
    Fig 8: Cross Vehicle Beam & Bolt
    G01672804Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the two vacuum lines from the defroster actuator (3).
  20. Disconnect the orange vacuum line from the recirculation actuator and install a hand vacuum pump (2).
  21. Remove the defroster actuator from its attachment to the HVAC module case.
  22. Using the hand vacuum pump (2) open the recirculation actuator door.
  23. 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.
  24. Disconnect the defroster actuator from the defroster door arm.
    Fig 9: Defroster Actuator, Vacuum Lines & Hand Vacuum Pump
    G01672805Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the vacuum lines from the mode actuator.
  26. Lift the lock tab up (1) to remove the actuator.
  27. Remove the mode actuator off the slides of the HVAC module assembly.
  28. Disconnect the actuator pushrod from the mode door lever and remove the actuator.
    Fig 10: Mode Actuator Lock Tab
    G01672806Courtesy of GENERAL MOTORS CORP.
  29. Remove the retaining screws (1) from the air distribution case cover.
  30. Remove the air distribution case cover (2).
  31. Remove and discard the air distribution case seal.
  32. Remove the linkage between the defroster door and the heater door on the left side of the HVAC module.
    Fig 11: Air Distribution Case Cover & Retaining Screws
    G01672807Courtesy of GENERAL MOTORS CORP.
  33. Remove the defroster door (1).
    Fig 12: Defroster Door
    G01672808Courtesy of GENERAL MOTORS CORP.
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