GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Uplander 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Temperature Door Replacement - Right Side

Removal Procedure

    Object Number: 1548548 Size: SH
  1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
  2. Remove the evaporator temperature sensor connector (1) from the case.

    3. Object Number: 1548546 Size: SH
  3. Remove the air inlet housing bolts/screws (1).

    4. Object Number: 1548550 Size: SH
  4. Remove the air inlet housing.

    5. Object Number: 1548542 Size: SH
  5. Remove the right side HVAC module bracket bolts/screws (1).
  6. Remove the right side HVAC module bracket (2).

    7. Object Number: 1548543 Size: SH

    Important: The upper HVAC module bolt/screw is located under the right HVAC module bracket.

  7. Remove the upper HVAC module bolt/screw.

    8. Object Number: 1548531 Size: SH
  8. Remove the HVAC module to dash panel sound barrier seal (1).

    9. Object Number: 1547644 Size: SH
  9. Remove the heater outlet duct bolts/screws.
  10. Remove the heater outlet duct.

    11. Object Number: 1547693 Size: SH
  11. Remove the heater core cover bolts/screws (1).
  12. Remove the heater core cover (2).

    13. Object Number: 1547694 Size: SH
  13. Remove the heater core pipe bolt/screw (1).
  14. Remove the heater core (2).

    15. Object Number: 1547696 Size: SH
  15. Remove the lower HVAC module bolts/screws (1).
  16. Separate the HVAC module case halves.

    17. Object Number: 1548534 Size: SH
  17. Remove the ride side air temperature actuator bolts/screws (1).
  18. Remove the right side air temperature actuator (2).
  19. Remove the right side air temperature actuator levers (3, 4, 5).
  20. Remove the right side air temperature door (6).

Installation Procedure

    Object Number: 1548534 Size: SH
  1. Install the right side air temperature door (6).

    2. Object Number: 1548535 Size: SH
  2. Install the right side air temperature actuator levers.

    3. Important: The actuator lever (2) can only be inserted into the door one way.

  3. Check and correct the engagement between the actuator levers (1, 2).
    4. 3.1. Install the actuator lever (2).
    3.2. Align the primary tooth (4) of the actuator lever (1) with the gap (3) in the actuator lever (2).

    Object Number: 1548534 Size: SH
  4. Install the right side air temperature actuator (2).

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

  5. Install the ride side air temperature actuator bolts/screws (1).

    6. Tighten
    Tighten the bolts/screws to 1.2 N·m (11 lb in).


    Object Number: 1547696 Size: SH

    Important: Align the temperature sensor wire with the opening in the upper HVAC case. Improper alignment will pinch and/or cut the sensor wire.

  6. Align and install the upper module case to the lower module case.
  7. Install the lower HVAC module bolts/screws (1).

    8. Tighten
    Tighten the bolts/screws to 1.2 N·m (11 lb in).


    Object Number: 1547694 Size: SH
  8. Install the heater core (2).
  9. Install the heater core pipe bolt/screw (1).

    10. Tighten
    Tighten the bolts/screws to 1.2 N·m (11 lb in).


    Object Number: 1547693 Size: SH
  10. Install the heater core cover (2).
  11. Install the heater core cover bolts/screws (1).

    12. Tighten
    Tighten the bolts/screws to 1.2 N·m (11 lb in).


    Object Number: 1547644 Size: SH
  12. Install the heater outlet duct.
  13. Install the heater outlet duct bolts/screws.

    14. Tighten
    Tighten the bolts/screws to 1.2 N·m (11 lb in).


    Object Number: 1548531 Size: SH
  14. Install the HVAC module to dash panel sound barrier seal (1).

    15. Object Number: 1548543 Size: SH
  15. Install the upper HVAC module bolt/screw.

    16. Tighten
    Tighten the bolt/screw to 1.2 N·m (11 lb in).


    Object Number: 1548542 Size: SH
  16. Install the right side HVAC module bracket (2).
  17. Install the right side HVAC module bracket bolts/screw (1).

    18. Tighten
    Tighten the bolts/screws to 1.4 N·m (12 lb in).


    Object Number: 1548550 Size: SH
  18. Install the air inlet housing.

    19. Object Number: 1548546 Size: SH
  19. Install the air inlet housing bolts/screws (1).

    20. Tighten
    Tighten the bolt/screw to 1.2 N·m (11 lb in).


    Object Number: 1548548 Size: SH
  20. Install the evaporator temperature sensor connector (1) to the case.
  21. Install the HVAC module. Refer to HVAC Module Assembly Replacement .
  22. Re-calibrate the actuators. Refer to Actuator Recalibration .