GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Impala 🢒 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. Disconnect the recirculation actuator electrical connector from the recirculation actuator.
  3. Remove the recirculation actuator electrical harness from the recirculation housing clips.
  4. Remove the screws that secure the recirculation housing to the HVAC module assembly.

    5. Object Number: 1263138 Size: SH
  5. Remove the recirculation housing from the HVAC module assembly.
  6. Disconnect the mode actuator electrical connector from the mode actuator.
  7. Remove the screws that secure the mode actuator to the HVAC module assembly.
  8. Remove the mode actuator from the HVAC module assembly.
  9. Disconnect the air temperature actuators electrical connector from the air temperature actuators.
  10. Remove the bolts that secure the TXV to the evaporator core.
  11. Remove the TXV from the evaporator core.
  12. Discard the old seal washers from the evaporator core.
  13. Remove the screws that secure HVAC module assembly upper case to the HVAC module assembly lower case.
  14. Remove the heat stakes that secure the HVAC module assembly upper case to the HVAC module lower case using a small chisel.

    15. Object Number: 295357 Size: SH
  15. Separate the HVAC module assembly case (1).

    16. Object Number: 295362 Size: SH
  16. Remove the evaporator core.

Installation Procedure
  1. If replacing the evaporator, add refrigerant oil to the evaporator. Refer to Refrigerant System Capacities for system capacity information.

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

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

    4. Object Number: 144107 Size: SH
  4. Install 2 new lower seals to the evaporator core.

    5. Object Number: 295362 Size: SH
  5. Install the evaporator core into the HVAC module assembly lower case.
  6. From the inside of the upper case, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit.

    7. Object Number: 295357 Size: SH
  7. Align and attach the upper and lower HVAC module assembly case.

    8. 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.

  8. Install the removed screws that secure the HVAC module assembly upper case to the HVAC module assembly lower case to their original position.

    9. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  9. Install new screws that will secure the HVAC module assembly upper case to the HVAC module assembly lower case in the locations adjacent to the heat stakes that were removed.

    10. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  10. Connect the air temperature electrical connector the air temperature actuator.
  11. Install the mode actuator.
  12. Install the screws that secure the mode actuator to the HVAC module assembly.

    13. Tighten
    Tighten the screws to 15 N·m (13 lb in).

  13. Connect the mode actuator electrical connector to the mode actuator.

    14. Object Number: 1263138 Size: SH
  14. Install the recirculation housing to the HVAC module assembly.
  15. Install the screws that secure the recirculation housing to the HVAC module assembly.

    16. Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  16. Route the recirculation actuator harness through the recirculation housing clips.
  17. Connect the recirculation actuator electrical connector to the recirculation actuator.
  18. Install new sealing washers on the evaporator core. Refer to Sealing Washer Replacement .
  19. Install the TXV to the evaporator core.
  20. Install the bolts that secure the TXV to evaporator core.

    21. Tighten
    Tighten the bolts to 7 N·m (62 lb in).

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