GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Defroster Door Replacement

Removal Procedure

    Object Number: 605190 Size: SH
  1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
  2. Remove the defroster actuator.
  3. Remove the defroster door spring.
  4. Remove the heater/defroster slave door linkage.

    5. Object Number: 605186 Size: SH
  5. Remove the screw for the mode/defroster door case cover retainer.
  6. Remove the retainer.

    7. Object Number: 605189 Size: SH
  7. Remove the mode/defroster door case cover screws.
  8. Remove the mode/defroster door case cover.

    9. Object Number: 604826 Size: SH
  9. Remove the defroster door (1) from the HVAC module assembly case.

Installation Procedure

    Object Number: 604826 Size: SH
  1. Install the defroster door (1) to the HVAC module assembly case.

    2. Object Number: 605189 Size: SH
  2. Install the mode/defroster door case cover.

    3. 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.

  3. Install the mode/defroster door case cover screws.

    4. Tighten
    Tighten the cover screws to 1 N·m (9 lb in).


    Object Number: 605186 Size: SH
  4. Install the mode/defroster door case cover retainer.
  5. Install the screw for the retainer.

    6. Tighten
    Tighten the retainer screws to 1 N·m (9 lb in).


    Object Number: 605190 Size: SH
  6. Install the defroster door spring.
  7. Install the heater/defroster slave door linkage.
  8. Install the defroster actuator.
  9. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement .