GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 GTO 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Temperature Door Replacement

Removal Procedure

    Object Number: 1378532 Size: SH
  1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
  2. Using a small screw driver disengage the locking tangs (3) securing the temperature door levers (2) to the temperature doors.
  3. Remove the temperature door levers and the return spring (4) from the HVAC unit (1).

    4. Object Number: 1376527 Size: SH
  4. Remove the thermal expansion valve (TXV) joint bracket screws (3) and remove the bracket (2) from the HVAC unit (1).
  5. Remove the heater core. Refer to Heater Core Replacement .

    6. Object Number: 1377581 Size: SH
  6. Disconnect the vacuum line (3) from the intake actuator.
  7. Remove the vacuum lines (5) and retainers (2) from the front HVAC module case (4).
  8. Remove the defroster actuator vacuum line from the defroster actuator (1).
  9. Remove the defroster actuator rod from the lever.
  10. Remove the defroster actuator retaining screws.

    11. Object Number: 1377587 Size: SH
  11. Remove the screws attaching the front HVAC module case to the upper HVAC module case and lower HVAC module case assembly.
  12. Separate the front HVAC module case from the upper HVAC module case and lower HVAC module case assembly.

    13. Object Number: 1377584 Size: SH
  13. Remove the screws (3, 5) attaching the HVAC module case - upper (1) to the HVAC module case - lower (6).
  14. Remove the clips (4) attaching the HVAC module case - upper to the HVAC module case - lower.
  15. Separate the HVAC module case - upper from the HVAC module case - lower.

    16. Object Number: 1376519 Size: SH
  16. Remove the temperature doors (2) from the HVAC module case.

Installation Procedure

    Object Number: 1376519 Size: SH
  1. Install the temperature doors (2) to the HVAC module case (3).

    2. Object Number: 1377584 Size: SH
  2. Align and install the HVAC module case - upper (1) to the HVAC module case - lower (6).
  3. Install the clips (4) attaching the HVAC module case - upper to the HVAC module case - lower.

    4. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the upper HVAC module case to the lower HVAC module case retaining screws (3, 5).

    5. Tighten
    Tighten the screws to 1.6 N·m (14 lb in).


    Object Number: 1377587 Size: SH
  5. Align and install the front HVAC module case to the upper HVAC module case and lower HVAC module case assembly.
  6. Install the front HVAC module case to the upper HVAC module case and lower HVAC module case assembly retaining screws.

    7. Tighten
    Tighten the screws to 1.6 N·m (14 lb in).


    Object Number: 1377581 Size: SH
  7. Install the defroster actuator (1) to the HVAC module assembly.
  8. Secure the defroster actuator with the retaining screws.

    9. Tighten
    Tighten the screws to 1.6 N·m (14 lb in).

  9. Install the defroster actuator rod to the lever.
  10. Install the defroster actuator vacuum line.
  11. Secure the retainers (2) and vacuum lines (5) to the HVAC module case - front (4).
  12. Connect the vacuum line (3) to the intake actuator.

    13. Object Number: 1376527 Size: SH
  13. Install the heater core. Refer to Heater Core Replacement .
  14. Install the TXV joint bracket (2) to the HVAC unit (1).
  15. Secure the bracket with the retaining screws (3).

    16. Tighten
    Tighten the screws to 1.6 N·m (14 lb in).


    Object Number: 1378532 Size: SH
  16. Install the temperature door levers (2) and the return spring (4) to the HVAC unit (1).
  17. Install the temperature door levers to the temperature doors.
  18. Install the HVAC module. Refer to HVAC Module Assembly Replacement .