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

Removal Procedure
  1. Remove the instrument panel (I/P) trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gages, and Console.
  2. Remove the bolt from the accessory wiring junction block.
  3. Disengage the junction block tabs from the passenger knee bolster. Remove the junction block from the knee bolster.
  4. Disconnect the booster push rod from the brake pedal.
  5. Remove the brake pedal. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  6. Remove the brake pedal brace bolts from the I/P carrier cross car beam.
  7. Lower the body control module (BCM) away from the I/P carrier.
  8. Disconnect any ground wires, as necessary.
  9. Reposition the I/P wiring harness out of the way.
  10. Remove the bracket bolts from the HVAC module center support.
  11. Remove the bracket bolts from the HVAC module upper support.
  12. Remove the bracket bolts from the HVAC module RH support.
  13. Remove the right and the left I/P carrier bolts.
  14. Remove the I/P carrier.

    15. Object Number: 1205474 Size: SH
  15. Remove the screws and the defroster air outlet duct.
  16. Remove the defroster air outlet duct.

Installation Procedure

    Object Number: 1205474 Size: SH
  1. Install the defroster air outlet duct.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the defroster air outlet duct screws.

    3. Tighten
    Tighten the screws 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).

  15. Install the I/P trim pad. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gauges, and Console.