GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 GTO 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Defroster Door Replacement

Removal Procedure

    Object Number: 1378449 Size: SH
  1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
  2. Remove the clip (9), actuator rod (8) and spacers (6) from the defroster door lever (5).
  3. Remove the screws (2) from the defroster duct (1) to HVAC module.
  4. Remove the defroster duct and door assembly from the HVAC module.
  5. Remove the screws (3) from the defroster door (7) to door shaft (4).
  6. Remove the defroster door from the defroster duct.

Installation Procedure

    Object Number: 1378449 Size: SH

    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.

  1. Install the defroster door (7) to the defroster door shaft (4). Secure the door with the screws (3).

    2. Tighten
    Tighten the screws to 0.8 N·m (7 lb in).

  2. Install the defroster duct and door assembly to the HVAC module. Secure the defroster duct (1) with the screws (2).

    3. Tighten
    Tighten the screws to 4 N·m (35 lb in).

  3. Install the actuator rod (8), spacers (6) and clip (9) to the defroster door lever (5).
  4. Install the HVAC module. Refer to HVAC Module Assembly Replacement .