GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Corvette 🢒 Body and Accessories 🢒 Waterleaks 🢒 Air Conditioning Evaporator Core Replacement

Removal Procedure

    Object Number: 295357 Size: SH
  1. Remove the HVAC module from the vehicle. Refer to HVAC Module Assembly Replacement
  2. Release the HVAC module vacuum harness from both of the harness retainers on the HVAC module case, below the air inlet housing.
  3. Remove the defroster valve vacuum actuator to better access the HVAC module case retaining screw which is under the actuator. Refer to Defroster Valve Actuator Replacement in Automatic System or Defroster Valve Actuator Replacement in Manual System.
  4. Remove the screws retaining the HVAC module case - upper to the HVAC module case - lower.

    5. To access the screw hidden under the air inlet valve, open the valve and retain in the open position.

  5. Release the retaining tab (1) securing the HVAC module case - upper to the HVAC module case - lower.
  6. Separate the HVAC module case - upper from the HVAC module case - lower.

    7. Object Number: 296249 Size: SH
  7. Remove and discard the HVAC module case seals.

    8. Start to remove the HVAC module case primary (blower motor side of case) seal (2) from the HVAC module case - lower at the position shown (1).


    Object Number: 295362 Size: SH
  8. Remove the evaporator core from the HVAC module case - lower.

    9. Object Number: 144107 Size: SH
  9. Remove and discard the evaporator core lower seals.

    10. Object Number: 144104 Size: SH
  10. Remove and discard the evaporator core upper seal.

    11. Object Number: 144106 Size: SH
  11. Remove and discard the evaporator core side seal.

    12. Object Number: 144102 Size: SH
  12. Remove and discard the evaporator core water core filter.

Installation Procedure

    Object Number: 628096 Size: SH
  1. Replacement evaporator core will come without refrigerant oil.
  2. If installing a replacement evaporator core, add 90 ml (3 oz) of refrigerant oil in the evaporator core.

    3. Object Number: 144102 Size: SH
  3. Install a new water core filter to the evaporator core.

    4. Object Number: 144106 Size: SH
  4. Install a new side seal to the evaporator core.

    5. Line the evaporator core side seal up with the corners of the evaporator core.


    Object Number: 144104 Size: SH
  5. Install a new upper seal to the evaporator core.

    6. Object Number: 144107 Size: SH
  6. Install two new lower seals to the evaporator core.

    7. Locate the seals at the outer corners (or edges) of the evaporator core.


    Object Number: 295362 Size: SH
  7. Install the evaporator core to the HVAC module case - lower.

    8. Object Number: 296253 Size: SH
  8. Install new case seals to the HVAC module case - lower.

    9. Start to install the HVAC module case primary (blower motor side of case) seal (2) to the HVAC module case - lower from the position shown (1).


    Object Number: 295357 Size: SH

    Important: Inspect the condition of the retaining tab on the HVAC module case - upper prior to installing to the HVAC module case - upper to the HVAC module case - lower. If the retaining tab is broken or damaged, install an external retaining clip (P/N 52458793, or equivalent).

  9. Align and install the HVAC module case - upper to the HVAC module case - lower.

    10. Align and secure the retaining tab (1) on the HVAC module case - upper to the retaining slot on the HVAC module case - lower.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  10. Install the HVAC module case - upper to the HVAC module case - lower retaining screws.

    11. Tighten
    Tighten the HVAC module case - upper to HVAC module case - lower retaining screws to 1.6 N·m (14 lb in).

  11. Install the defroster valve vacuum actuator. Refer to Defroster Valve Actuator Replacement
  12. Secure the HVAC module vacuum harness to both of the harness retainers on the HVAC module case, below the air inlet housing.
  13. Install the HVAC module to the vehicle. Refer to HVAC Module Assembly Replacement