Malibu, Malibu MAXX 2006-2008

Removal & Installation

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  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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