GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Malibu 🢒 Body Hardware and Trim 🢒 Instrument Panel and Console Trim 🢒 HVAC Module Assembly Replacement

Removal Procedure
  1. Remove the air conditioner (A/C) lines from the thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement.
  2. Remove the heater hose from the heater core. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement.
  3. Remove the instrument panel (I/P) assembly. Refer to Instrument Panel Reinforcement Replacement.
  4. Remove the recirculation actuator wire harness connector.
  5. Remove the air temperature actuator wire harness connector.
  6. Remove the mode actuator wire harness connector.
  7. Remove the blower motor wire harness connector.
  8. Remove the blower motor resistor wire harness connector.

    9. Object Number: 1203588 Size: SH
  9. Remove the left hand side window defogger outlet duct.

    10. Object Number: 1203547 Size: SH
  10. Remove the HVAC module assembly mounting bolts from the instrument panel reinforcement.

    11. Object Number: 1913704 Size: SH
  11. Remove the HVAC module assembly to dash panel bolts (1).

    12. Object Number: 1913702 Size: SH
  12. Remove the HVAC module assembly (1).

Installation Procedure

    Object Number: 1913702 Size: SH
  1. Install the HVAC module assembly (1).

    2. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1913704 Size: SH
  2. Install the HVAC module assembly to dash panel bolts (1) and tighten to 10 N·m (88 lb in).

    3. Object Number: 1203547 Size: SH
  3. Install the HVAC module assembly mounting bolts to the instrument panel reinforcement and tighten the bolts to 5 N·m (44 lb in).
  4. Install the left hand side window defogger outlet duct.

    5. Object Number: 1203580 Size: SH
  5. Install the blower motor resistor wire harness connector.
  6. Install the blower motor wire harness connector.
  7. Install the mode actuator wire harness connector.
  8. Install the air temperature actuator wire harness connector.
  9. Install the recirculation actuator wire harness connector.
  10. Install the I/P assembly. Refer to Instrument Panel Reinforcement Replacement.
  11. Install the heater hoses to the heater core. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement.
  12. Install the A/C lines to the thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement.