GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Cadillac 🢒 2003 🢒 CTS - RHD 🢒 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: 802735 Size: SH
  2. Remove the insulation (1) from the thermal expansion valve (TXV).

    3. Object Number: 817514 Size: SH
  3. Remove the HVAC line clamp screw.

    4. Object Number: 817516 Size: SH
  4. Remove the HVAC line clamp.

    5. Object Number: 802742 Size: SH
  5. Remove the TXV to evaporator bolts (1).

    6. Object Number: 802746 Size: SH
  6. Remove the TXV line bracket.

    7. Object Number: 802747 Size: SH
  7. Remove the TXV from the evaporator core.
  8. Separate the TXV from the A/C lines by pulling straight out.
  9. Remove the TXV.
  10. Remove the screws that hold the case together.

    11. Object Number: 756307 Size: SH
  11. Remove the clips that hold the case together.

    12. Object Number: 817507 Size: SH
  12. Disconnect the thermistor electrical connector.

    13. Object Number: 756343 Size: SH
  13. Separate the HVAC module.

    14. Object Number: 802751 Size: SH
  14. Remove the thermistor from the evaporator core.

    15. Object Number: 802748 Size: SH
  15. Remove the evaporator core.

Installation Procedure
  1. Add refrigerant oil. Refer to Refrigerant System Capacities .
  2. Install new evaporator core seals to evaporator.

    3. Object Number: 802748 Size: SH
  3. Install the evaporator core.

    4. Object Number: 802751 Size: SH
  4. Install the thermistor to the evaporator into the same position as removed.

    5. Object Number: 756343 Size: SH
  5. Slide the HVAC module together.

    6. 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.

  6. Install the screws that hold the case together.

    7. Tighten
    Tighten the screws to 1 N·m (8 lb in).

  7. Install the clips that hold the case together.

    8. Object Number: 817507 Size: SH
  8. Connect the thermistor electrical connector.
  9. Lube A/C lines with refrigerant oil before installing. Refer to O-Ring Replacement .
  10. Install the A/C lines into the TXV.

    11. Object Number: 802747 Size: SH
  11. Carefully slide the TXV onto the evaporator core until seated.

    12. Object Number: 802746 Size: SH
  12. Install the TXV line bracket.

    13. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 802742 Size: SH
  13. Install the TXV to evaporator bolts (1).

    14. Tighten
    Tighten the bolts to 3.5 N·m  (31 lb in).


    Object Number: 817516 Size: SH
  14. Install the HVAC line clamp.

    15. Object Number: 817514 Size: SH
  15. Install the HVAC line clamp screw.

    16. Tighten
    Tighten the screw to 1 N·m  (8 lb in).


    Object Number: 802735 Size: SH
  16. Install the insulation (1) onto the lines and TXV.
  17. Install the HVAC module. Refer to HVAC Module Assembly Replacement .