GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Grand Prix 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Distributor Duct Replacement

Removal Procedure
  1. Remove the instrument panel trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gages, and Console.

    2. Object Number: 1205471 Size: SH
  2. Remove the screws and the center air duct.

    3. Object Number: 1205479 Size: SH
  3. Remove the screws and the RH side air duct.

    4. Object Number: 1205480 Size: SH
  4. Remove the screws and the LH side air duct.
  5. Remove the bolt from the accessory wiring junction block.
  6. Disengage the junction block tabs from the passenger knee bolster. Remove the junction block from the knee bolster.
  7. Disconnect the booster push rod from the brake pedal.
  8. Remove the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  9. Remove the brake pedal brace bolts from the I/P carrier cross car beam.
  10. Lower the body control module (BCM) away from the I/P carrier.
  11. Disconnect any ground wires, as necessary.
  12. Reposition the I/P wiring harness out of the way.
  13. Remove the bracket bolts from the HVAC module center support.
  14. Remove the bracket bolts from the HVAC module upper support.
  15. Remove the right and the left I/P carrier bolts.
  16. Remove the I/P carrier.
  17. Remove the cross car air duct bolts from the I/P carrier.
  18. Remove the cross car air ducts from the I/P carrier.

Installation Procedure
  1. Install the cross car air ducts to the I/P carrier.

    2. 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.

  2. Install the cross car air duct bolts to the I/P carrier.

    3. Tighten
    Tighten the screw to 1.5 N·m (13 lb in).

  3. Install the I/P carrier to the vehicle. Align the I/P carrier to the HVAC module and the hinge pillars.
  4. Install the bolts to the right and the left I/P carrier.

    5. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  5. Install the bolts to the HVAC module upper support bracket.

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

  6. Install the bolts to the HVAC module center support bracket.

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

  7. Position the I/P wiring harness to the original position.
  8. Connect any disconnected ground wires.
  9. Install the BCM.
  10. Install the brake pedal brace bolts to the I/P carrier.
  11. Install the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  12. Install the booster push rod to the brake pedal.
  13. Seat the bottom junction block tabs and snap the top of the junction block to the passenger knee bolster.
  14. Install the junction block bolt.

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


    Object Number: 1205479 Size: SH
  15. Install the RH side air duct.
  16. Install the RH side air duct screws.

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


    Object Number: 1205480 Size: SH
  17. Install the LH side air duct.
  18. Install the LH side air duct screws.

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


    Object Number: 1205471 Size: SH
  19. Install the center air duct.
  20. Install the center air duct screws

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

  21. Install the instrument panel trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gages, and Console.