Called local dealer about the "clicking" when starting up, coming from passenger right corner. I was told it is a common problem and as others have written, with a $700.00 to 1k repair cost on a 37.00 part. I have searched past forums and have found multiple answers how others have fixed DIFFERENT vehicles in the past. Question is directed fo HHR owners. Nothing on youtube or other forums specific to this Blend Door Actuator repair other than the 27 step Auto Zone removal of the entire dashboard. Has anyone ever tried or documented the fix?

 

 

I saw a youtube the other day where a lady had taken the dash board apart then showed how to get your hand up there without taking it apart. That #4 in your illustration. It is held in by friction.

The door on the passenger side is the recirc door actuator. Many GM cars from the 2000's use the same box. Cobalt, G5, G6, Traverse, Impala, Malibu etc.

My youtube search for "hhr blend door replacement" yielded quite a few results, You could try other names.

 

doesn't work but I think I had seen this video. No actual HHR take aparts

 

thanks but wrong actuator, this is the one you can see looking up into the cabin filter

 

I don't know what you mean. The illustration you posted has id numbers on it.

Cobalt, G5, G6, Ion are identical and many others are very close.

Sorry, maybe you could document the job and post a how-to.

 

 

Its called the "Recirculation Actuator" Need to scroll down to it. Looks like a major job. If I decide to do it myself, I will make a video, 36 step process to get to it unless I can figure out a HACK
https://www.autozone.com/repairguide...96b43f80cb2dda

 

 

Then the youtube I posted is exactly the same actuator. My book says there is a screw, she says no screw.

If there is a screw you should be able to identify it's position by looking at the new part.