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

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: 1548532 Size: SH
  17. Remove the air temperature actuator bolts/screws (1).
  18. Remove the air temperature actuator (2).
  19. Remove the air temperature actuator lever (3).
  20. Remove the air temperature door (4).

Installation Procedure

    Object Number: 1548532 Size: SH
  1. Install the air temperature door (4).

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

  2. Install the air temperature actuator lever (3).
  3. Install the air temperature actuator (2).

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

  4. Install the air temperature actuator bolts/screws (1).

    5. 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.

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

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


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

    9. Tighten
    Tighten he bolts/screws to 1.2 N·m (11 lb in).


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

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


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

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


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

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

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


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

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


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

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

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


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