GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Malibu 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Air Conditioning Evaporator Core Replacement

Removal Procedure
  1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement.

    2. Object Number: 1701076 Size: SH
  2. Remove the center floor air outlet duct screws.
  3. Remove the center floor air outlet duct.

    4. Object Number: 1203558 Size: SH
  4. Drill out the lower HVAC module case heat stakes.
  5. Remove the lower HVAC module case screws.
  6. Remove the lower HVAC module case.

    7. Object Number: 1203577 Size: SH
  7. Remove the thermal expansion valve screws.
  8. Remove the thermal expansion valve.
  9. Remove and discard the sealing washers.

    10. Object Number: 1203561 Size: SH
  10. Remove the evaporator.

Installation Procedure
  1. If replacing the evaporator, add the specific amount of PAG® oil directly to the evaporator. Refer to Refrigerant System Capacities.

    2. Object Number: 1203561 Size: SH
  2. Install the evaporator.
  3. Install new sealing washers. Refer to Sealing Washer Replacement.

    4. Object Number: 1203577 Size: SH
  4. Install the thermal expansion valve.

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

  5. Install the thermal expansion valve screws and tighten to 7 N·m (62 lb in).

    6. Object Number: 1203558 Size: SH
  6. Install the lower HVAC module case.
  7. Install the lower HVAC module case screws and tighten to 1.5 N·m (13 lb in).

    8. Object Number: 1701076 Size: SH
  8. Install the center floor air outlet duct.
  9. Install the center floor air outlet duct screws and tighten to 1.5 N·m (13 lb in).
  10. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement.