GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Vacuum Hose Harness Replacement

Removal Procedure

    Object Number: 604567 Size: SH
  1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
  2. Disconnect the yellow hose (1) from the mode actuator (2).
  3. Disconnect the red hose (3) from the mode actuator (2).
  4. Remove the vacuum hose harness clips (4) from the HVAC module assembly.

    5. Object Number: 604565 Size: SH
  5. Disconnect the blue hose (1) from the defroster actuator (2).
  6. Disconnect the green hose (5) from the defroster actuator (2).
  7. Disconnect the violet hose (3) from the vacuum tank (4).
  8. Disconnect the orange hose (6) from the recirculation actuator (7).
  9. Remove the vacuum hose harness clip screw.
  10. Remove the vacuum hose harness.

Installation Procedure

    Object Number: 604565 Size: SH
  1. Position the vacuum hose harness.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the vacuum hose harness clip screw.

    3. Tighten
    Tighten the harness clip screw to 1 N·m (9 lb in).

  3. Connect the blue hose (1) to the defroster actuator (2).
  4. Connect the green hose (5) to the defroster actuator (2).
  5. Connect the violet hose (3) to the vacuum tank (4).
  6. Connect the orange hose (6) to the recirculation actuator (7).

    7. Object Number: 604567 Size: SH
  7. Connect the yellow hose (1) to the mode actuator (2).
  8. Connect the red hose (3) to the mode actuator (2).
  9. Install the vacuum hose harness clips (4) to the HVAC module assembly.
  10. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement .