GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2007 🢒 Malibu 🢒 Body Repair 🢒 Collision Repair 🢒 Plenum Upper 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 .
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  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 .

    6. Object Number: 1211375 Size: SH

    Important: Note the number and location of the factory welds for installation of the upper plenum panel.

  6. Locate and drill out all the necessary factory welds.

    7. Object Number: 1211376 Size: SH
  7. Remove the upper plenum panel.

Installation Procedure

    Object Number: 1211379 Size: SH

    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 locations noted from 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: 1211376 Size: SH
  4. Position the upper plenum panel to the vehicle using 3-dimensional measuring equipment. Clamp the panel in place.

    5. Object Number: 1211375 Size: SH
  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 .
  9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  11. Enable the SIR system. Refer to SIR Disabling and Enabling .