Malibu 2003 whatis a closeout panel - 2000 Chevrolet Malibu

Blend door is not working. Could be the door is stuck, wiring issue, bad actuator or control panel issue. In your car, the actuator is not too hard to access. Follow the instructions to access the actuator. Check the connection. Before removing the actuator, turn the key on and change the temp setting. If you hear clicking from the actuator, it has probably stripped its gears. If not, remove the actuator and check to see if you can rotate the door by hand. If not, you will need to remove the duct to see why the door is jammed. If the door rotates by hand, plug the connector back into the actuator, turn the key on again, and change the temp setting while watching the gear on the actuator to verify operation. If the actuator doesn't turn the gear, the problem is with the actuator or the controller. Remove the connector again and probe the connector with a voltmeter. Turn the key on again and probe the terminal of the light blue wire. There should be voltage there when you change the temp setting. If not, the problem is with the control panel. If there is voltage of a few volts or more, the problem is the actuator.

Removal & Installation

Remove the fuse labeled HVAC CTRL (BATT).
Remove the left closeout panel.
Remove the knee bolster.
Remove the air temperature actuator screws.
Remove the air temperature actuator.
Remove the air temperature actuator wire harness connector.


To install:

Install the air temperature actuator wire harness connector.
Install the air temperature actuator and tighten the mounting screws to 13 inch. lbs. (1.5 Nm).
Install the knee bolster
Install the left closeout panel.
Install the fuse labeled HVAC CTRL (BATT).

Preliminary Procedure
Remove the instrument panel left outer trim panel. Refer to Instrument Panel Outer Trim Cover Replacement .
Remove the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side .
Remove the data link connector.
1
Screws, Knee Bolster (Qty: 3)
Tighten
2 N·m (18 lb in)
2
Knee Bolster Assembly
3
Retaining Clip, Knee Bolster (Qty: 3)

Callout
Component Name
Notice: Refer to Fastener Notice in the Preface section.
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications .
1
Screw, Instrument Panel Closeout/Insulator (Qty: 2)
Tighten
2 N·m (18 lb in)
2
Nut, Instrument Panel Closeout/Insulator (Qty: 1)
Tighten
2 N·m (18 lb in)
3
Panel Assembly, Instrument Panel Closeout/Insulator

Removal Procedure
Remove the fuse labeled HVAC CTRL (BATT).
Remove the left closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side .
Remove the knee bolster. Refer to Knee Bolster Replacement .
Remove the mode actuator retaining screws.
Remove the mode actuator.
Disconnect the mode actuator electrical connector.

The turn/hazard flasher module is probably bad .
Removal Procedure

1. Remove the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages and Console.
   
   
2. 
3. Remove the flasher retaining bracket from the insulator panel.
4. Disconnect the flasher from the electrical connector.
5. Remove the flasher from the vehicle.

Turn Signal/Hazard Flasher Module
Behind the I/P near the headlamp switch

Fuse Box Diagram Chevrolet Malibu (1997-2003)

https://fuse-box.info > chevrolet > chevrolet-malibu-19...
It is located on the driver's side of the instrument panel, behind the cover. The location of the fuses in the passenger compartment: Chevrolet Malibu (1997, ...

check the fuse panel under the dash in front of the driver seat.

REMOVAL & INSTALLATION 2.4L Engine

1. Disconnect the negative battery cable at the battery.
2. Detach the air inlet duct from the throttle body.
3. Position a drain pan under the oil filter, then remove the oil filter.
4. Remove the top starter bolt.
5. Raise and safely support the vehicle.
6. Remove the lower starter retaining bolt.
7. If necessary, position the engine wiring harness aside.
8. Position the starter to enable access to the solenoid wiring, then detach the wiring.
9. Remove the starter from the vehicle. To install:
   
10. Raise the starter to the vehicle, then attach the wiring.
11. Position the starter, then secure using the lower starter bolt. Tighten to 66 ft. lbs. (90 Nm). Fig. 1: When installing the starter on the 2.4L engine, tighten the mounting bolts to 66 ft. lbs. (90 Nm)
    
    
12. If moved, reposition the engine wiring harness.
13. Attach the solenoid electrical connectors.
14. Carefully lower the vehicle.
15. Install the top starter bolt, then tighten to 66 ft. lbs. (90 Nm).
16. Replace the oil filter.
17. Fasten the air inlet duct to the throttle body.
18. Connect the negative battery cable.
19. Check the oil level and add if necessary.
20. Start the engine, recheck the oil level and add if necessary.

3.1L Engine

1. Disconnect the negative battery cable.
2. Raise and safely support the front of the vehicle securely on jackstands.
3. Remove the lower closeout panel.
4. Remove the electrical leads. Fig. 2: Two electrical leads connect to the starter solenoid. The larger one has battery power as long as the battery is connected. The smaller one only has power when the key is turned to START
   
   
5. Remove the starter motor to engine bolts, then remove the starter from the vehicle. To install:
   
6. Install the starter. Position one engine-to-starter bolt in the lower bolt hole, then finger-start the bolt.
7. Connect the electrical leads to the starter. Tighten the cable to the solenoid to 106 inch lbs. (12 Nm).
8. Install the starter-to-engine bolts and tighten to 37 ft. lbs. (50 Nm)
9. Install the lower closeout panel.
10. Lower the vehicle.
11. Connect the negative battery cable.

Suspect it is the blend door actuator, but please see my tip at http://www.fixya.com/cars/r6235876-no_heat_fan_blowing_cold_air . These are generic instructions. If you get stuck or need specific instructions for your car, please get back to me with model, year and engine info. Below are instructions for replacing the blend door actuator, but don't replace it unless you're sure it's bad. Autozone has it for $36. First, take it out, plug the connector back in and see if it turns when you change the temperature control. If not, the problem can be in the controller or the actuator. If it is clicking, the problem is stripped gears. If it isn't doing anything, you can check for voltage at the connector with a voltmeter. Connect the black meter lead to a good ground point and probe the connector terminals with the red lead while changing the temperature setting.

Blend door actuator removal and installation:

Remove the fuse labeled HVAC CTRL (BATT).

Remove the left closeout panel.

Remove the knee bolster.

Remove the air temperature actuator screws.

Remove the air temperature actuator.

Remove the air temperature actuator wire harness connector.

Fig. Air temperature actuator removal
To install:

1. Install the air temperature actuator wire harness connector.
2. Install the air temperature actuator and tighten the mounting screws to 13 inch. lbs. (1.5 Nm).
3. Install the knee bolster
4. Install the left closeout panel.
5. Install the fuse labeled HVAC CTRL (BATT).

the clips are all around door. about 7 or 8 inches apart. on both sides and bottom. use a flat blade or similar to pop clips loose on panal. when clips are loosened, then roll down window and slide panal upward to remove. good luck!!

Wow I hope youre mechanicly inclined, big job the entire dash & carrier have to come out 7-15 hr job if you know what you are doing to much to list hear I would check heater hoses at fire wall first make sure they arnt leaking. I wish you well