How to Change a Heater Fan on a 2004 Malibu

Once the highest trim level of a popular muscle car and now a timid family car; the Malibu has made a drastic change since its 1964 debut as the Chevelle Malibu. The 2004 model year was the second generation for the Malibu since its reintroduction in 1997 and featured harder body lines and a more stylish appearance. As expected of a midlevel family car, the 2004 Malibu came standard with an air-conditioning system that used a small electric fan to circulate the heated or cooled air. Upon first look, the blower motor may appear non-replaceable, as Chevy molded it with the heating and air-conditioning box, but a sharp utility knife and some elbow grease can take care of that.

Instructions

Removal

1

Adjust the passengers seat as far back as it will go and find the closeout panel, the trim panel on the underside of the dashboard. Pry downward on the edge of the panel nearest the passengers seat, using a flat-head screwdriver, to disengage the retaining clips.

2

Pull downward sharply on the closeout panel to disengage the remaining retaining clips. Lower the panel just enough to access the wiring harness clips. Pry the wiring harness clips from the panel, using a flat-head screwdriver.

3

Find the blower motor under the passengers side of the dashboard. Unplug the wiring harness from the blower motor.

4

Find the narrow groove around the blower motors perimeter. Using a utility knife with a new blade, cut through the narrow groove to free the blower motor, as it is one molded piece with the heating and air-conditioning box. When there is just an inch of the groove remaining, hold the blower motor so it does not fall and cut the last inch of plastic. If your blower motor has screws holding it, this means the motor has been replaced by a previous owner. Hold the blower motor with one hand and remove the retaining screws with a ratchet and socket.

5

Lower the blower motor from the heating and air-conditioning box.

Installation

6

Guide the seal, which comes with the new blower motor, onto the blower motors mounting base. Lift the blower motor into place and align its screw holes with the pre-existing screw holes in the heating and air-conditioning box.

7

Tighten the self-tapping screws, which come with the new motor, to 13 inch-pounds, using an inch-pound torque wrench and socket. Plug the wiring harness into the blower motors receptacle.

8

Hold the closeout panel close enough to the underside of the dashboard for the wiring harness clips to reach their slots in the panel. Press the wiring harness clips into their respective slots in the panel.

9

Line up the closeout panels retaining clips with the slots under the dashboard and press the panel upward to snap them into place.