GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 2004 🢒 Rendezvous - AWD 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Temperature Door Replacement - Left Side

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

    2. Object Number: 860415 Size: SH
  2. Remove the left hand temperature door lever bolt (3) from the HVAC module.
  3. Disconnect and remove the left hand temperature door lever spring (2).
  4. Disconnect and remove the left hand temperature door lever (1) from the left hand temperature door.

    5. Object Number: 825400 Size: SH
  5. Remove the air inlet housing retaining screws.
  6. Remove the air inlet housing.

    7. Object Number: 825399 Size: SH
  7. Remove the right HVAC module mounting bracket screws.
  8. Remove the right HVAC module mounting bracket.

    9. Important: The HVAC module assembly upper retaining screw is located under the right HVAC module assembly mounting bracket.

  9. Remove the HVAC module upper retaining screw.

    10. Object Number: 825392 Size: SH
  10. Remove the HVAC module assembly to dash panel sound barrier seal.

    11. Object Number: 825398 Size: SH
  11. Remove the screws retaining the heater outlet duct.
  12. Remove the heater outlet duct.

    13. Object Number: 825396 Size: SH
  13. Remove the heater core cover screws.
  14. Remove the heater core cover.

    15. Object Number: 825397 Size: SH
  15. Remove the heater core pipe retaining screw.
  16. Remove the heater core.

    17. Important: The lower HVAC module assembly retaining screw is located behind the heater core.

  17. Remove the lower HVAC module retaining screw.

    18. Object Number: 825389 Size: SH
  18. Remove the lower HVAC module screws.
  19. Separate the HVAC module case halves.

    20. Object Number: 868474 Size: SH
  20. Remove the left hand air temperature door.

Installation Procedure

    Object Number: 868474 Size: SH
  1. Install the left hand air temperature door.

    2. Object Number: 825389 Size: SH

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

  2. Align and install the upper module case to the lower module case.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the lower HVAC module screws.

    4. Tighten
    Tighten the screws to 0.9 N·m (8 lb in).

  4. Install the lower HVAC module retaining screw.
  5. Install the heater core.

    6. Object Number: 825397 Size: SH
  6. Install the heater core pipe retaining screw.

    7. Tighten
    Tighten the screw to 0.9 N·m (8 lb in).


    Object Number: 825396 Size: SH
  7. Install the heater core cover.
  8. Install the heater core cover screws.

    9. Tighten
    Tighten the screws to 0.9 N·m (8 lb in).


    Object Number: 825398 Size: SH
  9. Install the heater outlet duct.
  10. Install the heater outlet duct screws.

    11. Tighten
    Tighten the screws to 0.9 N·m (8 lb in).

  11. Install the HVAC module upper retaining screw.

    12. Tighten
    Tighten the screw to 0.9 N·m (8 lb in).


    Object Number: 825399 Size: SH
  12. Install the right HVAC module mounting bracket.
  13. Install the right HVAC module mounting bracket screws.

    14. Tighten
    Tighten the screw to 1.8 N·m (16 lb in).


    Object Number: 825392 Size: SH
  14. Install the HVAC module assembly to dash panel sound barrier seal.

    15. Object Number: 825400 Size: SH
  15. Install the air inlet housing.
  16. Install the air inlet housing screws.

    17. Tighten
    Tighten the screws to 0.9 N·m (8 lb in).

    Important: Align the pin on the left hand air temperature actuator with the slot in the left hand temperature door lever.

  17. Install the left hand temperature door lever (1) to the left hand temperature door.

    18. Object Number: 860415 Size: SH
  18. Connect the left hand temperature door lever spring (2) to the left hand temperature door lever (1) and HVAC module case.
  19. Install the left hand temperature door lever bolt (3) to the HVAC module case.

    20. Tighten
    Tighten the bolt to 0.9 N·m (8 lb in).

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