Malibu, Malibu MAXX 2006-2008

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Recover the refrigerant.
  4.  
  5. Disable the Supplemental Inflatable Restraint (SIR) system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Drain the coolant.
  10.  
  11. Remove the HVAC module assembly.
  12.  
  13. Remove the lower center floor air outlet duct.
  14.  
  15. Remove the upper center floor air outlet duct screws
  16.  
  17. Remove the upper center floor air outlet duct.
  18.  
  19. Remove the air inlet assembly screws.
  20.  
  21. Remove the air inlet assembly.
  22.  
  23. Remove the air temperature actuator screws.
  24.  
  25. Remove the air temperature actuator
  26.  
  27. Remove the mode actuator screws
  28.  
  29. Remove the mode actuator.
  30.  
  31. Drill out the mode valve assembly heat stakes.
  32.  
  33. Remove the mode valve assembly screws.
  34.  
  35. Remove the mode valve assembly.
  36.  
  37. Drill out the lower HVAC module case heat stakes.
  38.  
  39. Remove the lower HVAC module case screws.
  40.  
  41. Remove the lower HVAC module case.

    Click image to see an enlarged view

    Fig. Lower HVAC module case removal

  42.  
  43. Remove the thermal expansion valve screws.
  44.  
  45. Remove the thermal expansion valve.
  46.  
  47. Remove and discard the sealing washers
  48.  
  49. Remove the evaporator.

    Click image to see an enlarged view

    Fig. Evaporator core removal

  50.  

To install:

  1. If replacing the evaporator core, add 1.5 oz PAG® oil directly to the evaporator core.
  2.  
  3. Install the evaporator.
  4.  
  5. Install the thermal expansion valve and tighten the screws to 62 inch. lbs. (7 Nm).
  6.  
  7. Install the lower HVAC module case.
  8.  
  9. Install the lower HVAC module case screws and tighten to 13 inch. lbs. (1.5 Nm).
  10.  
  11. Install the mode valve assembly and tighten the mounting screws to 13 inch. lbs. (1.5 Nm).
  12.  
  13. Install the mode actuator and tighten the mounting screws to 13 inch. lbs. (1.5 Nm).
  14.  
  15. Install the air temperature actuator and tighten the mounting screws to 13 inch. lbs. (1.5 Nm).
  16.  
  17. Install the air inlet assembly. Tighten the screws to 13 inch. lbs. (1.5 Nm).
  18.  
  19. Install the upper center floor air outlet duct and tighten the mounting screws to13 inch. lbs. (1.5 Nm).
  20.  
  21. Install the lower center floor air outlet duct.
  22.  
  23. Install the HVAC module assembly.
  24.  
  25. Evacuate and charge the A/C system.
  26.  
  27. Enable SIR system.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Leak test the fittings.
  32.  

 
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