GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 L200/LW200 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Rear Floor Air Outlet Replacement

Removal Procedure
  1. Move the seat to the full forward position and remove the front seat fasteners.
  2. Disable the SIR. Refer to SIR Disabling and Enabling in SIR.

    3. Object Number: 896651 Size: SH
  3. Remove the front seat outer shoulder belt outer valance.
  4. Remove the shoulder belt from the seat frame.

    5. Object Number: 896861 Size: SH
  5. Pull the seat assembly slightly rearward to disengage the seat from the front seat track hooks.
  6. Tilt the seat rearward and disconnect the seat wiring harnesses.
  7. Remove the seat from the vehicle and place the seat on a clean protected work surface.

    8. Object Number: 896493 Size: SH
  8. Gently pull on the left and right side console extensions to remove the extensions.

    9. Object Number: 896945 Size: SH
  9. Power Window Vehicles Only: Using a small flat-bladed tool, gently pry upward on the rear portion of the power window switch to partially disengage the switch from the console.
  10. Disconnect the power window switch harness from the switch and remove the power window switch.

    11. Object Number: 896592 Size: SH
  11. Disengage the console park brake boot by squeezing the boot in the locations shown while pulling upward.
  12. Lift the park brake boot over the park brake assembly.

    13. Object Number: 896503 Size: SH
  13. Remove the front console tray by pulling upward on the tray assembly.
  14. Disconnect the console wiring harness from the main body harness.

    15. Object Number: 893814 Size: SH
  15. Automatic Transaxle Vehicles Only: Pull up on the PRNDL cover to disengage the cover.

    16. Object Number: 895322 Size: SH
  16. For 5-Speed Transaxle Vehicles Only: Pull up on the shifter boot to disengage the boot.

    17. Object Number: 896495 Size: SH
  17. Remove the rear console fasteners.
  18. Remove the front console fasteners.
  19. Gently lift the console up and over the shifter or PRNDL cover and remove the console assembly.

    20. Object Number: 892666 Size: SH
  20. Slide the connector duct left/right adapter upward.

    21. Object Number: 881410 Size: SH
  21. Remove the carpet retainer.
  22. Pull back the carpet at driver/passenger footwell to expose the duct.

Installation Procedure

    Object Number: 893456 Size: SH
  1. Install the duct over the floor studs. Press down to engage the duct onto the studs.

    2. Object Number: 892666 Size: SH
  2. Slide the connector duct adapter down to seal against the rear duct.

    3. Object Number: 881410 Size: SH
  3. Install the front carpet by tucking the carpet under the HVAC unit and under the shift rod. Ensure the carpet is properly placed to prevent wrinkles.
  4. Position the carpet retainer into the vehicle.
  5. Starting at rear of the vehicle, snap the carpet retainer into the hinge pillar molding.
  6. Position the carpet retainer over the remaining attaching clip locations.
  7. Gently push on the attaching clips to install the carpet retainer.
  8. Install the weatherstrip over the carpet retainer using a flat-bladed tool.

    9. Object Number: 896495 Size: SH
  9. Position the console into the vehicle. Route the shifter/PRNDL boot through the console opening.

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

  10. Install the front console fasteners.

    11. Tighten
    Tighten the fasteners to 2.5 N·m (22 lb in).


    Object Number: 893814 Size: SH
  11. Automatic Transaxle Vehicles Only: Snap the PRNDL cover into the console opening.

    12. Object Number: 895322 Size: SH
  12. 5-Speed Transaxle Vehicles Only: Snap the shifter boot into the console opening.
  13. Connect the console wiring harness to the main body harness.

    14. Object Number: 896503 Size: SH
  14. Install the tray into the front console and snap the tray into place.
  15. Power Window Vehicles Only: Connect the power window harness to the power window switch and snap the switch into place.

    16. Object Number: 896592 Size: SH
  16. Install the park brake boot into the console and snap the boot into place.

    17. Object Number: 896493 Size: SH
  17. Install the console extensions.

    18. Object Number: 896651 Size: SH
  18. Position the seat into the vehicle.
  19. Tilt the seat rearward and connect the seat wiring harnesses.
  20. Slide the seat into the forward tracks.
  21. Apply Loctite 242® Threadlocker or equivalent to the seat fasteners.
  22. Install the seat fasteners.

    23. Tighten
    Tighten the fasteners to 25 N·m (19 lb ft).

  23. Install the shoulder belt to the seat frame.
  24. Install the shoulder belt to the seat frame bolts.

    25. Tighten
    Tighten the bolts to 35 N·m (26 lb ft).

  25. Install the shoulder belt outer valance.
  26. Enable the SIR. Refer to SIR Disabling and Enabling in SIR.
  27. If equipped, operate the electrical seat components to ensure proper operation.