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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 156 (HVAC SYSTEMS - MANUAL)REPAIR INSTRUCTIONSMODE ACTUATOR REPLACEMENTREMOVAL PROCEDURE
2001 Chevrolet Cavalier LS, 2.4 T

Removal Procedure

2001 Chevrolet Cavalier LS, 2.4 TSECTION Removal Procedure
WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the I/P upper trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) UPPER in Instrument Panel, Gages and Console.
  2. Remove the instrument panel cluster (IPC) to steering column bracket retaining screws.
    Fig 1: Removing Instrument Panel Cluster To Steering Column Bracket Retaining Screws
    G01418856Courtesy of GENERAL MOTORS CORP.
  3. Reposition the IPC to better access the inside air temperature sensor duct.
  4. Remove the driver knee bolster bracket. Refer to BRACKET REPLACEMENT - KNEE BOLSTER (DRIVER) or BRACKET REPLACEMENT - KNEE BOLSTER (DRIVER OUTER) or BRACKET REPLACEMENT - KNEE BOLSTER (PASSENGER) in Instrument Panel, Gages and Console.
  5. Disconnect the ignition switch lock cylinder electrical connector from the retaining tab on the side of the ignition switch.
    Fig 2: Disconnecting Ignition Switch Lock Cylinder Electrical Connector From Retaining Tab
    G01418857Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the lock cylinder electrical connector.

    Important:  Take note of how the ignition switch lock cylinder wire is wrapped around the base of the ignition switch bezel.

  7. Remove the ignition switch bezel.

    Carefully pull to unsnap.

    Fig 3: Disconnecting Lock Cylinder Electrical Connector
    G01418858Courtesy of GENERAL MOTORS CORP.
  8. Remove the hazard warning switch wiring harness from the ignition switch retainer.
    Fig 4: Removing Hazard Warning Switch Wiring Harness From Ignition Switch Retainer
    G01418859Courtesy of GENERAL MOTORS CORP.
  9. Remove the ignition switch retaining bolts.
    Fig 5: Removing Ignition Switch Retaining Bolts
    G01418860Courtesy of GENERAL MOTORS CORP.
  10. Reposition the ignition switch downward.
  11. Disconnect the vacuum harness connectors from the mode actuator.
    Fig 6: Disconnecting Vacuum Harness Connectors From Mode Actuator
    G01418861Courtesy of GENERAL MOTORS CORP.
  12. Lift to release the mode actuator retaining tab and just begin to slide the actuator toward the steering column bracket.
  13. Remove the air distribution case cover bolts.
  14. Remove the air distribution case cover with the mode actuator attached.
  15. Position the pod of the mode actuator between the steering column bracket and the ignition switch housing bracket.
  16. Disconnect the mode actuator pushrod from the mode door lever and remove the actuator.
  17. Remove the mode actuator from the mode door lever.
    Fig 7: Removing Mode Actuator
    G01418862Courtesy 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.