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

Removal Procedure

    Object Number: 604127 Size: SH
  1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
  2. Remove the heater core. Refer to Heater Core Replacement .
  3. Remove the heater core case shroud screw and shroud.

    4. Object Number: 639965 Size: SH
  4. Remove the screws and evaporator core brackets.

    5. Object Number: 639966 Size: SH
  5. Remove the evaporator core.

Installation Procedure

    Object Number: 639966 Size: SH
  1. If you are installing a NEW evaporator core add the proper quantity of refrigerant oil to the evaporator core. Refer to Refrigerant Oil Distribution .
  2. Install the evaporator core.

    3. Object Number: 639965 Size: SH

    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 evaporator core brackets and screws.

    4. Tighten
    Tighten the screws to 1 N·m (9 lb in).


    Object Number: 604127 Size: SH
  4. Install the heater core case shroud.
  5. Install the heater core case shroud screws.

    6. Tighten
    Tighten the screws to 1 N·m (9 lb in).

  6. Install the heater core. Refer to Heater Core Replacement .
  7. Install the HVAC module. Refer to HVAC Module Assembly Replacement .