2004 Chevy 2dr Cavalier Sport Edition Loud Popping Noise When HACV switch is in all positions but Recirculate

CARLTONRIDES

MEMBER
2004 CHEVROLET CAVALIER
4 CYL
FWD
AUTOMATIC
79,000 MILES

My daughter's '04 Cavalier has a loud popping noise when one actuates any position other than the AC Recircluate position, whether at no or any fan speed position as well. This steady popping noise will happen even when car is not started and ignition is activated. I have been reading online forums about this issue, and I'm guessing that his to do with the motor which actuates the fresh air plastic door. Does stop making noise when in recirculate mode because door is closed in this mode? Therefore the door is trying to open in the other modes, and something is broken like a plastic part the motor pushes/pulls? More importantly, what will fix this and do you have 'do it yourself' instructions? Thanks

3 Replies

TWLIGHTNING

MEMBER
2 POSTS

Mine is doing the exact same thing. How do you get to the fresh air door to replace the actuator or whatever is makeing that noise.

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Friday, October 14th, 2011 AT 1:57 PM

TWLIGHTNING

MEMBER
2 POSTS

Figured it out. You have to remove the dash pad, air ducts, passenger air bag, and the actuator is to the right of the door. I caught it making the noise when I hooked the battery back up to double check that was what was making the noise. Please follow a manual when your messing with your airbags.