GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 L300/LW300 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Mode Door Replacement

Removal Procedure
  1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .

    2. Object Number: 892670 Size: SH
  2. Remove the mode actuator screws.
  3. Remove the mode actuator.

    4. Object Number: 892694 Size: SH
  4. Remove the mode cam.

    5. Object Number: 892695 Size: SH
  5. Remove the primary lever screws.
  6. Remove the primary levers.

    7. Object Number: 892696 Size: SH
  7. Remove the sub-levers with a flat-bladed screwdriver.

    8. Object Number: 892697 Size: SH
  8. Remove the recirculation actuator screws.
  9. Remove the recirculation actuator.

    10. Object Number: 894750 Size: SH
  10. Remove the temperature door actuator.

    11. Object Number: 894256 Size: SH
  11. Open the heater core pipe connector collars and remove.

    12. Clamps may need to be rotated to gain access to the retaining tab.

  12. Pull the heater core pipes out of the heater core and through the HVAC module case to remove.

    13. Object Number: 894259 Size: SH
  13. Remove the heater core retainer.
  14. Remove the heater core from the module.

    15. Object Number: 894339 Size: SH
  15. Turn the module upside down.
  16. Remove the lower case screws and remove the lower case.
  17. Separate the case halves.
  18. Remove the evaporator and TXV seal assembly by lifting straight up.

    19. Object Number: 892701 Size: SH
  19. Turn the module right side up, and use a razor blade to cut the defroster/vent seal, and blower motor opening seal at the center line.

    20. Object Number: 894314 Size: SH
  20. Release the recirculation door connecting rod from the retainer.
  21. Remove the rod from the small door lever and remove.
  22. Remove the large and small recirculation doors.

    23. Object Number: 894361 Size: SH

    Important: 

       • There are 2 clips and 9 screws. Two of the screws are located in deep cavities.
       •  One screw is located at the center of the case.

  23. Remove the case half retainer clips and screws.

    24. Object Number: 892704 Size: SH
  24. With case laying on the left side, lift the right side straight up to separate the HVAC module.

    25. Object Number: 894376 Size: SH
  25. Remove the doors from the HVAC case:
    26. • Temperature
    • Defrost
    • Vent
    • Heater
    • Mode

Installation Procedure

    Object Number: 894376 Size: SH
  1. Install the doors into the HVAC case:
    2. • Mode
    • Heater
    • Vent
    • Defrost
    • Temperature
  2. Install the right side of case, carefully lining up door shafts with case openings.
  3. Verify that each door can be easily rotated through out the doors entire motion.

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


    Object Number: 894361 Size: SH
  4. Install the HVAC module screws and clips.

    5. Tighten
    Tighten the screws to 1.0 N·m (9 lb in).


    Object Number: 894339 Size: SH
  5. Install the evaporator into the bottom of the HVAC module.
  6. Install the lower case to the upper case.
  7. Install the lower module screws.

    8. Tighten
    Tighten the screws to 1.0 N·m (9 lb in).


    Object Number: 894259 Size: SH
  8. Install the heater core into the case.

    9. Object Number: 894256 Size: SH

    Important: Verify that both pipes have a bushing and O-ring installed before installing into the heater core.

  9. Install the heater pipes through the case and into the heater core.

    10. The shorter pipe is the upper pipe.

  10. Install the heater pipe retaining clamps.

    11. Important: The lower heater pipe clamp hinge fits into the tab on the heater core retainer strap.

  11. Install the heater core retaining strap.

    12. Object Number: 893650 Size: SH
  12. Install the evaporator and TXV seal assembly.

    13. Object Number: 894314 Size: SH
  13. Install the recirculation doors.
  14. Install recirculation door rod to small door.

    15. With both doors held firmly closed, snap rod into retainer clip and close the clip.


    Object Number: 892697 Size: SH
  15. Install the recirculation actuator assembly onto door shaft.

    16. The shaft has two flats that must be aligned to actuator.

  16. Install the recirculation actuator bracket to module screws.

    17. Tighten
    Tighten the screws to 1.0 N·m (9 lb in).


    Object Number: 892696 Size: SH
  17. Install the vent and heater sub-levers.

    18. These sub-levers are identical and should have the slotted end facing inward.

  18. Install the defrost door to sub-lever.

    19. Object Number: 892695 Size: SH
  19. Install the vent primary lever.
  20. Install the vent primary lever fastener.

    21. Tighten
    Tighten the fastener to 1.0 N·m (9 lb in).

  21. Install the heater primary lever.
  22. Install the heater primary lever fastener.

    23. Tighten
    Tighten the fastener to 1.0 N·m (9 lb in).


    Object Number: 892694 Size: SH
  23. Install the cam.

    24. Rotate the cam to verify proper installation.


    Object Number: 892670 Size: SH
  24. Install the mode actuator.
  25. Install the mode actuator fastener.

    26. Tighten
    Tighten the fastener to 1.0 N·m (9 lb in).

  26. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement .