Malibu 2001-2005

Removal & Installation

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  1. Disable the air bag by performing the following procedure:
    1. Place the front wheel in the straight-ahead position.
    2.  
    3. Turn the ignition switch to the LOCK position.
    4.  
    5. Remove the air bag fuse from the fuse block.
    6.  
    7. At the left side, remove the sound insulator.
    8.  
    9. At the driver-s side, disconnect the Connector Position Assurance (CPA) and the yellow 2-way electrical connectors and the lead to the passenger-s side SIR module.
    10.  

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Disconnect the heater hoses from the heater core and remove the drain tube from the heater/air conditioning housing.
  8.  
  9. Remove the steering wheel by removing or disconnecting the following:
    CAUTION
    Place the SIR module in a safe place with the front facing upward.



    2 SIR module-to-steering wheel screws (located at the rear of the steering wheel), and the module
     
    SIR module and disconnect the electrical connector and remove the SIR module
     



    Horn and cruise control electrical connectors
     
    Steering wheel-to-steering column nut
     
    Steering wheel from the steering column
     

  10.  
  11. Remove the console by removing or disconnecting the following:

    Front seats
     
    Fold the console compartment upward
     
    Console trim plate
     
    Rear cup holder
     
    Console-to-chassis screws and the console
     

  12.  
  13. Remove the instrument panel by removing or disconnecting the following:
    NOTE
    There is a screw located in the recess in the center of the cover.



    Defroster grille
     
    Instrument panel valance screws and the valance
     
    Instrument panel end caps from both sides
     
    Screws located under the instrument panel end caps
     
    Instrument panel compartment
     
    Steering column covers
     
    Steering column stalks
     
    Instrument cluster and accessory trim plates
     
    Instrument cluster fasteners, disconnect the electrical connectors and remove the cluster
     
    Heater/air conditioning control assembly
     
    Stereo/tape deck assembly
     
    Ignition switch
     
    Upper windshield side garnish molding
     
    Loosen the center console, pull it rearward to disengage it from the instrument panel
     
    Instrument panel-to-tie bar screws
     
    Instrument panel
     
    Outlet from the heater/air conditioning housing
     
    Heater core cover-to-heater/air conditioning housing
     



    Heater core-to-heater/air conditioning housing clamps
     
    Heater core

    Click image to see an enlarged view

    Fig. Exploded view of the console and related components-Cutlass and Malibu



    Click image to see an enlarged view

    Fig. View of instrument panel-Cutlass and Malibu



    Click image to see an enlarged view

    Fig. View of the evaporator core, upper heater/air conditioning housing and related components-Cutlass and Malibu



    Click image to see an enlarged view

    Fig. View of the heater core, lower heater/air conditioning housing and related components-Cutlass and Malibu

     

  14.  

To install:

  1. Install or connect the following:
    NOTE
    There is a screw located in the recess in the center of the cover.



    Heater core
     
    Heater core-to-heater/air conditioning housing clamps
     
    Heater core cover-to-heater/air conditioning housing
     



    Outlet to the heater/air conditioning housing
     

  2.  
  3. Install the instrument panel by installing or connecting the following:

    Instrument panel
     
    Instrument panel-to-tie bar screws
     
    Move the center console forward and engage it to the instrument panel
     
    Upper windshield side garnish molding
     
    Ignition switch
     
    Stereo/tape deck assembly
     
    Heater/air conditioning control assembly
     
    Instrument cluster, connect the electrical connectors and install the cluster fasteners
     
    Instrument cluster accessory trim plates
     
    Steering column stalks
     
    Steering column covers
     
    Instrument panel compartment
     
    Instrument panel end caps, install the screws
     
    Instrument panel end caps on both sides
     
    Instrument panel valance and the valance screws
     
    Defroster grille
     

  4.  
  5. Install the console by installing or connecting the following:

    Console and the console-to-chassis screws
     
    Rear cup holder
     
    Console trim plate
     
    Front seats
     

  6.  
  7. Install the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-steering column nut and torque to 30 ft. lbs. (41 Nm)
     
    Horn and cruise control electrical connectors
     
    SIR module and connect the electrical connector
     
    SIR module and torque the 2 module-to-steering wheel screws to 89 inch lbs. (10 Nm)
     
    Heater hoses to the heater core and install the drain tube to the heater/air conditioning housing
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Enable the SIR or air bag by installing or connecting the following:

    Connector Position Assurance (CPA), the yellow 2-way electrical connectors and the lead to the passenger-s side SIR module (located on the drivers- side)
     
    Sound insulator, located on the left side
     
    Air bag fuse to the fuse block
     

    1. Turn the ignition switch to RUN and verify that the Air Bag Warning light flashes 7-9 times and turns OFF.
      NOTE
      If the SIR system does not operate as described, perform the SIR diagnostic system check.

    2.  

  14.  
  15. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disable the Supplemental Inflatable Restraint (SIR) system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the coolant.
  8.  
  9. Remove the inlet heater hose at the heater core.
  10.  
  11. Remove the outlet heater hose at the heater core.
  12.  
  13. Recover the refrigerant.
    NOTE
    Cap all A/C components immediately to prevent system contamination.

  14.  
  15. Remove the suction hose at the Thermostatic Expansion Valve (TXV).
  16.  
  17. Remove the liquid line at the TXV.
  18.  
  19. Remove and discard the sealing washers.
  20.  
  21. Disconnect the HVAC module to front of dash plate bolts.
  22.  
  23. Remove the right console trim panel.
  24.  
  25. Remove the left console trim panel.
  26.  
  27. Remove the console.

    Click image to see an enlarged view

    Fig. Console front mounting screw location



    Click image to see an enlarged view

    Fig. Console front mounting screw location

  28.  
  29. Remove the left closeout panel.
  30.  
  31. Remove both Instrument Panel (I/P) outer trim panels.
  32.  
  33. Remove the I/P to the body wire harness and antenna LH connectors.
  34.  
  35. Remove the I/P to the wire harness RH connectors.
  36.  
  37. Remove the knee bolster.
  38.  
  39. Remove the accelerator pedal.
  40.  
  41. Remove the steering column to the I/P wire harness connector.
  42.  
  43. Remove the crush bracket to the front of dash plate nuts.
  44.  
  45. Remove the upper steering column shroud from the lower shroud.
  46.  
  47. Remove the stalk switches and the SIR coil connectors.
  48.  
  49. Position the steering wheel in full forward telescoping position.
  50.  
  51. Position the front seat in the full rearward position.
  52.  
  53. Remove the steering column mounting bolts.
  54.  
  55. Lower the steering column to the floor.
  56.  
  57. Remove the brake pedal assembly.
  58.  
  59. Remove the Body Control Module (BCM).
  60.  
  61. Remove the center support bracket floor bolts.
  62.  
  63. Remove the shifter assembly.
  64.  
  65. Remove both windshield pillar garnish moldings.
  66.  
  67. Remove the I/P upper trim panel.
  68.  
  69. Remove the I/P body LH bolts.

    Click image to see an enlarged view

    Fig. Instrument panel body LH bolts shown

  70.  
  71. Remove the I/P body RH bolts.
  72.  
  73. Remove the right hand floor heater duct at the center floor heater duct.
  74.  
  75. Remove the left hand floor heater duct at the center floor heater duct.
  76.  
  77. Remove the I/P assembly.
  78.  
  79. Remove the recirculation actuator wire harness connector.
  80.  
  81. Remove the air temperature actuator wire harness connector.
  82.  
  83. Remove the mode actuator wire harness connector.
  84.  
  85. Remove the blower motor wire harness connector.
  86.  
  87. Remove the blower motor resistor wire harness connector.
  88.  
  89. Remove the left hand side window defogger outlet duct.
  90.  
  91. Remove the lower floor duct push-in fastener.
  92.  
  93. Remove the HVAC module assembly mounting bolts.
  94.  
  95. Remove the HVAC module assembly.

    Click image to see an enlarged view

    Fig. HVAC module assembly mounting bolts shown



    Click image to see an enlarged view

    Fig. HVAC module assembly removal

  96.  
  97. Remove the lower center floor air outlet duct
  98.  
  99. Remove the upper center floor air outlet duct screws.
  100.  
  101. Remove the upper center floor air outlet duct
  102.  
  103. Drill out the heater core cover heat stakes.
  104.  
  105. Remove the heater core cover screws.
  106.  
  107. Remove the heater core cover.
  108.  
  109. Remove the heater core.

    Click image to see an enlarged view

    Fig. Heater core removal

  110.  

To install:

  1. Install heater core.
  2.  
  3. Install the heater core cover.
  4.  
  5. Install heater core screws and tighten to 13 inch. lbs. (1.5 Nm).
  6.  
  7. Install the upper center floor air outlet duct.
  8.  
  9. Install the upper center floor air outlet duct screws and tighten to 13 inch. lbs. (1.5 Nm).
  10.  
  11. Install the lower center floor air outlet duct.
  12.  
  13. Install the HVAC module assembly.
  14.  
  15. Install the HVAC module assembly mounting bolts and tighten to 44 inch. lbs. (5 Nm).
  16.  
  17. Install the lower floor duct push-in fastener.
  18.  
  19. Install the left hand side window defogger outlet duct.
  20.  
  21. Install the blower motor resistor wire harness connector.
  22.  
  23. Install the blower motor wire harness connector.
  24.  
  25. Install the mode actuator wire harness connector.
  26.  
  27. Install the air temperature actuator wire harness connector.
  28.  
  29. Install the recirculation actuator wire harness connector.
  30.  
  31. Install the I/P assembly.
  32.  
  33. Install the left hand floor heater duct at the center floor heater duct.
  34.  
  35. Install the right hand floor heater duct at the center floor heater duct.
  36.  
  37. Install the I/P body RH/LH bolts and tighten to 19 ft. lbs. (26 Nm).
  38.  
  39. Install the I/P upper trim panel.
  40.  
  41. Install both windshield pillar garnish moldings.
  42.  
  43. Install the shifter assembly.
  44.  
  45. Install the center support bracket floor bolts and tighten to 89 inch. lbs. (10 Nm).
  46.  
  47. Install the BCM and tighten mounting screws to 22 inch. lbs. (2.5 Nm).
  48.  
  49. Install the brake pedal assembly tighten bolts to 18 ft. lbs. 25 Nm), tighten nuts to 11 ft. lbs. (15 Nm).
  50.  
  51. Install the steering column assembly and tighten bolts starting with the lower bolt first then left to right. Tighten to 18 ft. lbs. (27 Nm).
  52.  
  53. Install the stalk switches and the SIR coil connectors.
  54.  
  55. Install the upper steering column shroud and tighten screws to 13 inch. lbs. (1.5 Nm).
  56.  
  57. Install the crush bracket to the front of dash plate nuts and tighten to 89 inch. lbs. (10 Nm).
  58.  
  59. Install the steering column to the I/P wire harness connector.
  60.  
  61. Install the accelerator pedal.
  62.  
  63. Install the knee bolster.
  64.  
  65. Install the I/P to the body wire harness RH connectors.
  66.  
  67. Install the I/P to the body wire harness and antenna LH connectors.
  68.  
  69. Install both I/P outer trim panels.
  70.  
  71. Install the left closeout panel.
  72.  
  73. Install the console and tighten mounting bolts and screws to 10 inch. lbs. (1 Nm).
  74.  
  75. Install the left and right console trim panel
  76.  
  77. Install the HVAC module to front of dash plate bolts and tighten to 35 inch. lbs. (4 Nm).
  78.  
  79. Install new sealing washers.
  80.  
  81. Install the liquid line and the suction hose at the TXV.
  82.  
  83. Tighten the liquid line and suction hose nut to 15 ft. lbs. (20 Nm).
  84.  
  85. Evacuate and charge the refrigerant system.
  86.  
  87. Install the outlet and inlet heater hoses at the heater core, tighten the clamps.
  88.  
  89. Fill and bleed the cooling system.
  90.  
  91. Enable the SIR system.
  92.  
  93. Connect the negative battery cable.
  94.  

 
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