Was waxing the Malibu before winter and noticed the front headlights were scorched.  Replaced the lenses with knock offs from ebay and used gm recommended 3157K LCP bulbs.



Here's the TSB from GM

Subject:Front Park/Turn Signal/DRL or Rear Stop/Turn Signal/Tail Lamp/Light Inoperative (Replace Bulb and Inspect Socket) #06-08-42-004B - (06/19/2006)

Models:2004-2006 Chevrolet Malibu, Malibu Maxx


This bulletin is being revised with updated parts information in the Correction section. Please discard Corporate Bulletin Number 06-08-42-004A (Section 08 - Body & Accessories).
Condition

Some customers may comment that the front park/turn/DRL or rear stop/turn/tail lamp is inoperative.
Correction

DO NOT REPLACE THE HEADLAMP OR TAIL LAMP ASSEMBLY.
Replace the bulb and inspect the socket. If the socket is discolored, replace the socket following the procedures below.
Front Park/Turn/DRL Lamp
  1. <LI type=1>Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement in SI. <LI type=1>Inspect the socket.
    • If the socket is NOT discolored or damaged, replace the bulb only with Osram 3157 LCP bulb, P/N 13502322.
    • If the socket is discolored at the bulb interface, replace the socket and bulb.
    Important: Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures.
    1. Cut the wires of the park/turn/DRL socket approximately 45 mm (1-¾ in) from the socket and splice in the replacement socket, P/N 15945363. Ensure that the splice is not above the socket when re-installing.
    2. Replace the bulb with Osram 3157 LCP bulb, P/N 13502322.
  2. Verify that the front park/turn/DRL lamp is fully functional.
Rear Stop/Turn/Tail Lamp
  1. <LI type=1>Remove the lamp assembly, then remove the lower bulb (stop/turn/tail). Refer to Tail Lamp Assembly and/or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement in SI. <LI type=1>Inspect the socket.
    • If the socket is NOT discolored or damaged, replace the bulb only with Osram 3057 LCP bulb, P/N 15883346.
    • If the socket is discolored at the bulb interface, replace the socket and bulb.
    Important: Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures.
    1. Cut the wires of the stop/turn/tail socket approximately 45 mm (1-¾ in) from the socket and splice in the replacement socket (P/N 15873724 for Malibu sedans or P/N 15873725 for Malibu Maxx vehicles).
    2. Replace the bulb with Osram 3057 LCP bulb, P/N 15883346.
    <LI type=1>Remove the upper bulb (auxiliary tail lamp), if needed, and inspect the auxiliary tail lamp socket for discoloration. If the auxiliary tail lamp socket has discoloration, install new socket, P/N 15876348.
  2. Verify that the rear stop/turn/tail lamp is fully functional.
Parts Information

Part Number
Description
15883346
Osram 3057 LCP Bulb
13502322
Osram 3157 LCP Bulb
15945363
Socket Asm - Front Park & T/Sig Lp
15873724
Socket Asm - Stop & T/Lp (Malibu Sedan)
15873725
Socket Asm - Stop & T/Lp (Malibu Maxx)
15876348
Socket Asm - T/Lp
Important: A full rear harness with both new sockets is available for collision repair. Refer to the Parts Catalog for new part number usage and availability.
<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1841159&evc=numSrch#ss4-1841159">Warranty Information

For vehicles repaired under warranty, use:
Labor Operation
Description
Labor Time
N0680
Bulbs, Park And Turn Signal Lamp (Right) - Replace
Use Published Labor Operation Time
N0681
Bulbs, Park And Turn Signal Lamp (Left) - Replace
N0760
Bulbs, Stop, Tail, And Turn Lamp (Right) - Replace
N0761
Bulbs, Stop, Tail, And Turn Lamp (Left) - Replace
N9537*
Socket, Lamp - Exterior (Front) - Replace
0.2 hr
Add:
To Splice Turn Signal Socket
0.1 hr
N9538*
Socket, Lamp - Exterior (Rear) - Replace
0.2 hr
Add:
To Splice Turn Signal/Stop Lamp and Auxiliary Tail Lamp
0.1 hr
*This labor operation is for bulletin use only. It will not be published in the Labor Time Guide.
If only bulbs are replaced, use labor operation N0680, N0681, N0760 and/or N0761.
__________________

Here are some new pictures after disassembling the headlights and I used them in a letter I mailed to GM complaining of this problem.



So I got upset and then started tearing the assemblies apart and started to prep them for paint.  It was a lot of work but the best way to separate the assembly was to heat the oven to 200F and shut it off and put the assembly in for 10 minutes.  After that it came apart pretty easily after working the edges with a large metal scraper/spatula.  Here is some of the prep.  I kept the burnt amber lenses but took them to a grinder and doubled the size of the hole compared to the scorch mark.