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HOMESERVICE MANUALSCHEVROLET1999PICKUP K1500, 5.7 RREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 449 (HEATING, VENTILATION AND AIR CONDITIONING)REPAIR INSTRUCTIONSDEFROSTER DOOR REPLACEMENTINSTALLATION PROCEDURE
1999 Chevrolet Pickup K1500, 5.7 R

Installation Procedure

1999 Chevrolet Pickup K1500, 5.7 RSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the defroster door.
    Fig 1: Installing Defroster Door
    G01499054Courtesy of GENERAL MOTORS CORP.
  2. Install the air distribution cover.
  3. Install the air distribution cover screws.

    Tighten 

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

    Fig 2: Installing Air Distribution Cover Screws
    G01499055Courtesy of GENERAL MOTORS CORP.

    Important:  Align the slot on the defroster door lever with the pin on the mode door main lever.

  4. Connect the defroster door lever (2) and the defroster door spring (1) to the defroster door.
  5. Connect the defroster door spring (1) to the air distribution cover.
    Fig 3: Connecting Defroster Door Spring
    G01499056Courtesy of GENERAL MOTORS CORP.

    Important:  Align the slot on the secondary defroster door lever with the pin on the mode door main lever.

  6. Connect the secondary defroster door lever to the secondary defroster door.
    Fig 4: Connecting Secondary Defroster Door Lever
    G01499057Courtesy of GENERAL MOTORS CORP.
  7. Install the right HVAC module mounting bracket to the HVAC module assembly.
  8. Install the right HVAC module mounting bracket screws.

    Tighten 

    Tighten the screws to 1.8 N.m (16 lb in).

  9. Install the left HVAC module mounting bracket to the HVAC module assembly.
  10. Install the left HVAC module mounting bracket screws.

    Tighten 

    Tighten the screws to 1.8 N.m (16 lb in).

  11. Install the I/P carrier. Refer to INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT .
    Fig 5: Installing Right HVAC Module Mounting Bracket Screws
    G01499058Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.