GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Malibu 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Distributor Duct Replacement

Removal Procedure

    Object Number: 593711 Size: SH
  1. Remove the instrument panel (IP) carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges, and Console.
  2. Remove the cross vehicle beam (tie bar). Refer to Instrument Panel Tie Bar Replacement in Instrument Panel, Gauges and Console.
  3. Remove the defroster duct. Refer to Defroster Air Outlet Replacement .
  4. Remove the right side window defogger duct. Refer to Side Window Defogger Outlet Duct Replacement - Right Side .
  5. Remove the left side window defogger duct. Refer to Side Window Defogger Outlet Duct Replacement - Left Side .
  6. Unsnap the lap air duct from the air distribution duct.

    7. Object Number: 593716 Size: SH
  7. Remove the wiring harness from the left end of the air distribution duct.
  8. Remove the air distribution duct bolts.
  9. Remove the air distribution duct from the vehicle.

Installation Procedure

    Object Number: 593711 Size: SH
  1. Install the air distribution duct on the pins of the HVAC module assembly.

    2. 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.

  2. Install the air distribution bolts.

    3. Tighten
    Tighten the air distribution duct bolts to 3 N·m (27 lb in).


    Object Number: 593716 Size: SH
  3. Install the wiring harness to the left end of the air distribution duct.
  4. Snap the lap duct to the air distribution duct.
  5. Install the left side window defogger duct. Refer to Side Window Defogger Outlet Duct Replacement - Left Side .
  6. Install the right side window defogger duct. Refer to Side Window Defogger Outlet Duct Replacement - Right Side .
  7. Install the defroster duct. Refer to Defroster Air Outlet Replacement .
  8. Install the cross vehicle beam (tie bar). Refer to Instrument Panel Tie Bar Replacement in Instrument Panel, Gauges and Console.
  9. Install the instrument panel (IP) carrier. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges, and Console.