GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Cavalier 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Evaporator Tube Replacement

Removal Procedure
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the hood closeout filler panel. Hood Close Out Filler Replacement in Body Front End.

    3. Object Number: 631421 Size: SH
  3. Disconnect the coolant surge tank lines at the surge tank.

    4. Object Number: 302601 Size: MH
  4. Remove the evaporator tube to condensor nut in order to disconnect the connection from the condenser (3). Discard the O-ring seal.
  5. Remove the tube from the retaining clip (6) located on the body side rail (2.4L only).
  6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  7. Remove the tube from the evaporator. Discard the O-ring seals.
  8. Lower the vehicle.
  9. Remove the evaporator tube (4).

Installation Procedure

    Object Number: 302601 Size: MH
  1. Set the evaporator tube (4) in place.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    3. 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.

  3. Install the tube to the evaporator. Use new O-ring seals.

    4. Tighten
    Tighten the fitting to 24 N·m (18 lb ft).

  4. Lower the vehicle.
  5. Install the tube to the retraining clip (6) located on the body side rail (2.4L only).
  6. Install the evaporator tube to the condenser (3). Use the new O-ring seals.

    7. Tighten
    Tighten the nut to 16 N·m (12 lb ft).


    Object Number: 631421 Size: SH
  7. Connect the coolant surge tank lines to the surge tank.
  8. Install the hood closeout filler panel. Hood Close Out Filler Replacement in Body Front End.
  9. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging .
  10. Check for leaks. Refer to Leak Testing .