HVAC System - Automatic: Removal & Installation Chevrolet Malibu VI facelift

Removal Procedure

1. Remove the instrument panel (I/P) center trim panel. Refer to «Instrument Panel Center Trim Panel Replacement»(ref-269117-S16268385712007102900000) .
2. Remove the HVAC control module screws.
3. Remove the HVAC control module.
4. Remove the HVAC control module wire harness connectors.

Installation Procedure

1. Install the HVAC control module wire harness connectors.
2. Install the HVAC control module.
3. Tighten the HVAC control module screws. Tighten: Tighten the screws to 2.5 N.m (22 lb in).
4. Install the I/P center trim panel. Refer to «Instrument Panel Center Trim Panel Replacement»(ref-269117-S16268385712007102900000) .
5. Start the engine and let run for one minute.
6. Refer to «Control Module References»(ref-269146-S40400118222007102900000) for programming and setup information.

1. Remove the right closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(ref-269117-S16932106312007102900000) .
2. Remove the blower motor control processor wire harness connector.
3. Remove the blower motor control processor screws.
4. Remove the blower motor control processor.

1. Install the blower motor control processor.
2. Tighten the blower motor control processor screws. Tighten: Tighten the blower motor resistor screws to 1.5 N.m (13 lb in).
3. Install the blower motor control processor wire harness connector.
4. Install the right closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(ref-269117-S16932106312007102900000) .

1. Remove the fuse labeled HVAC CTRL (BATT).
2. Remove the right closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(ref-269117-S16932106312007102900000) .
3. Remove the communication interface module. Refer to «Communication Interface Module Replacement»(ref-269121-S19028472992007102900000) .
4. Remove the OnStar module bracket. Refer to «Bracket Assembly Replacement - OnStar Module»(ref-269121-S38613507542007102900000) .
5. Remove the recirculation door actuator screws.
6. Remove the recirculation door actuator.
7. Remove the recirculation door actuator wire harness connector.

1. Install the recirculation door actuator wire harness connector.
2. Install the recirculation door actuator.
3. Tighten the recirculation door actuator screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
4. Install the OnStar module bracket. Refer to «Bracket Assembly Replacement - OnStar Module»(ref-269121-S38613507542007102900000) .
5. Install the communication interface module. Refer to «Communication Interface Module Replacement»(ref-269121-S19028472992007102900000) .
6. Install the right closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Right Side»(ref-269117-S16932106312007102900000) .
7. Install the fuse labeled HVAC CTRL (BATT).

1. Remove the fuse labeled HVAC CTRL (BATT).
2. Completely open instrument panel (I/P) compartment door by pressing both tabs that support the stop bumpers. Refer to «Instrument Panel Compartment Replacement»(ref-269117-S20648741212007102900000) .
3. Remove the mode actuator wire harness connector.
4. Remove the mode actuator screws.
5. Remove the mode actuator.

1. Install the mode actuator.
2. Install the mode actuator screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
3. Install the mode actuator wire harness connector.
4. Close I/P compartment door. Refer to «Instrument Panel Compartment Replacement»(ref-269117-S20648741212007102900000) .
5. Install the fuse labeled HVAC CTRL (BATT).

1. Remove the fuse labeled HVAC CTRL (BATT).
2. Remove the left closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-269117-S39105054882007102900000) .
3. Remove the knee bolster. Refer to «Knee Bolster Replacement»(ref-269117-S04905620782007102900000) .
4. Remove the air temperature actuator screws.
5. Remove the air temperature actuator.
6. Remove the air temperature actuator wire harness connector.

1. Install the air temperature actuator wire harness connector.
2. Install the air temperature actuator.
3. Tighten the air temperature actuator screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
4. Install the knee bolster. Refer to «Knee Bolster Replacement»(ref-269117-S04905620782007102900000) .
5. Install the left closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-269117-S39105054882007102900000) .
6. Install the fuse labeled HVAC CTRL (BATT).

1. Remove the left closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-269117-S39105054882007102900000) .
2. Remove the knee bolster. Refer to «Knee Bolster Replacement»(ref-269117-S04905620782007102900000) .
3. Twist and pull the upper air temperature sensor from the upper right air outlet duct.
4. Remove the upper air temperature sensor wire harness connector.

1. Install the upper air temperature sensor wire harness.
2. Install the upper air temperature sensor.
3. Install the knee bolster. Refer to «Knee Bolster Replacement»(ref-269117-S04905620782007102900000) .
4. Install the left closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-269117-S39105054882007102900000) .

1. Remove the right console trim panel. Refer to «Front Floor Console Side Trim Panel Replacement - Right Side»(ref-269117-S03426108632007102900000) .
2. Twist and pull the lower air temperature sensor from the center floor air outlet duct.
3. Remove the lower air temperature sensor wire harness.

1. Install the lower air temperature sensor wire harness.
2. Install the lower air temperature sensor.
3. Install the right console trim panel. Refer to «Front Floor Console Side Trim Panel Replacement - Right Side»(ref-269117-S03426108632007102900000) .