Procedure for the Removal and Installation of the Windshield Defroster Nozzle Duct Assembly

Since 1991, the service procedure for removal of the windshield defroster nozzle duct assembly has required the removal of the instrument panel and HVAC module. This procedure differed from the Sedan and Wagon procedure due to the sharper windshield angle on the Coupe. Attempting to remove a windshield defroster nozzle duct assembly from a Coupe, using the Sedan/Wagon procedure, often resulted in the lower attachment tabs on the windshield defroster nozzle duct assembly being damaged. If damaged, the windshield defroster nozzle duct assembly cannot be properly attached to the HVAC module and windshield defrosting performance could be affected.

The windshield Defroster nozzle duct assembly can be from the top without damage, with the instrument panel and HVAC module installed in the vehicle. Due to the high level of labor required to remove the instrument panel and HVAC module, and the relatively low cost of a new windshield defroster nozzle duct assembly, a new removal and installation procedure will now be used.

The windshield defroster nozzle duct assembly on the Coupe will be serviced using the Sedan/Wagon procedure, which is currently in the HVAC Service Manual, with the installation of a new windshield defroster nozzle duct assembly required. This new procedure will benefit the customer by reducing the labor cost and vehicle repair time. Coupe windshield defroster nozzle duct assembly labor time will now change due to the new procedure.

The new procedure for replacing the windshield defroster nozzle duct assembly on a Coupe is added to this bulletin for your convenience.

Windshield Defroster Nozzle Duct Assembly -- Coupe

1. Disable the SIR system. Refer to Disabling the SIR System in the SIR Service Manual.
2. Remove the screws and unsnap the windshield defroster nozzle duct assembly from the mode valve assembly.
3. Remove the windshield defroster nozzle duct assembly by rotating the front of the nozzle up and away from the windshield.

1. Snap the new windshield defroster nozzle duct assembly onto the mode valve assembly and install the screws.

Tighten
Tighten the screws to 2.2 N·m (20 lb in).

2. Enable the SIR system. Refer to Enabling the SIR System in the SIR Service Manual.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System using the appropriate Electronic Labor Guide and Labor Operation Code D1430 (Duct Assembly, Defroster -- Replace, w/o A/C), or D1432 (Duct Assembly, Defroster -- Replace, w/ A/C).