GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Cavalier 🢒 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. Remove the heat stakes and the screws from the upper case assembly.

    3. Object Number: 864405 Size: SH
  3. Remove the cam cable and the screw.
  4. Remove the upper case assembly.

    5. Object Number: 868828 Size: SH
  5. Remove the heat stakes and the screws from the heater cover.
  6. Remove the heater cover.

    7. Object Number: 868734 Size: SH
  7. Remove the evaporator core.

Installation Procedure

    Object Number: 868734 Size: SH
  1. If you are installing a new evaporator core, add the same quantity of refrigerant oil to the new evaporator core. Refer to Refrigerant System Capacities .
  2. Install the evaporator core.

    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 upper case assembly and the screws.

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


    Object Number: 864405 Size: SH
  4. Install the cam cable and the screw.

    5. Object Number: 868828 Size: SH
  5. Install the heater cover and the screws and sealant.

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

  6. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement .