GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Malibu 🢒 Body 🢒 Collision Repair 🢒 Plenum Lower Panel Replacement

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    3. Important: This panel is replaced at factory seams.

  3. Remove all related panels and components.
  4. Repair as much of the damage as possible. Refer to Dimensions - Body .
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.

    6. Object Number: 1211404 Size: SH
  6. Locate and drill out all the necessary factory welds.

    7. Object Number: 1211407 Size: SH
  7. Locate and drill out all of the necessary factory welds at the following locations:
    8. • The dash panel to the lower plenum
    • The inside ends of the lower plenum
    • On the top rear portion of the front upper rail to the plenum

    Object Number: 1211409 Size: SH
  8. Remove the lower plenum panel from the vehicle.

Installation Procedure

    Object Number: 1211410 Size: SH

    Important: The service part comes as an assembly that includes the lower dash panel. If the repair does not require the dash panel, remove the dash panel before you install the lower plenum panel.

    Important: If you cannot determine the location of the original plug weld holes, space the plug weld holes every 40 mm (1½ in) apart.

  1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel.
  2. Prepare all mating surfaces as necessary.
  3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

    4. Object Number: 1211404 Size: SH
  4. Position the lower plenum panel to the vehicle.
  5. Plug weld accordingly.
  6. Clean and prepare all of the welded surfaces.
  7. Install all of the related panels and components.
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  11. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.