GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu Classic 🢒 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. Remove the lower center floor air outlet duct.
  3. Remove the upper center floor air outlet duct screws.
  4. Remove the upper center floor air outlet duct.

    5. Object Number: 1203597 Size: SH
  5. Remove the air inlet assembly screws.
  6. Remove the air inlet assembly.

    7. Object Number: 1203548 Size: SH

    Object Number: 1203576 Size: SH
  7. Remove the air temperature actuator screws.
  8. Remove the air temperature actuator.
  9. Remove the mode actuator screws.

    10. Object Number: 1203571 Size: SH
  10. Remove the mode actuator.
  11. Drill out the mode valve assembly heat stakes.

    12. Object Number: 1203569 Size: SH
  12. Remove the mode valve assembly screws.
  13. Remove the mode valve assembly.
  14. Drill out the lower HVAC module case heat stakes.
  15. Remove the lower HVAC module case screws.

    16. Object Number: 1203558 Size: SH
  16. Remove the lower HVAC module case.
  17. Remove the thermal expansion valve screws.
  18. Remove the thermal expansion valve.

    19. Object Number: 1203577 Size: SH
  19. Remove and discard the sealing washers

    20. Object Number: 1203561 Size: SH
  20. 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. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the thermal expansion valve screws.

    6. Tighten
    Tighten the screws to 7 N·m (62 lb in).


    Object Number: 1203558 Size: SH
  6. Install the lower HVAC module case.
  7. Install the lower HVAC module case screws.

    8. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  8. Install the mode valve assembly.

    9. Object Number: 1203569 Size: SH
  9. Install the mode valve assembly screws.

    10. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  10. Install the mode actuator.

    11. Object Number: 1203571 Size: SH
  11. Install the mode actuator screws.

    12. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  12. Install the air temperature actuator.

    13. Object Number: 1203576 Size: SH
  13. Install the air temperature actuator screws.

    14. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  14. Install the air inlet assembly.

    15. Object Number: 1203548 Size: SH
  15. Install the air inlet assembly screws.

    16. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  16. Install the upper center floor air outlet duct.

    17. Object Number: 1203597 Size: SH
  17. Install the upper center floor air outlet duct screws.

    18. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  18. Install the lower center floor air outlet duct.
  19. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement .