GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Lumina 🢒 Body and Accessories 🢒 Waterleaks 🢒 Air Conditioning Evaporator Core Replacement

Removal Procedure
  1. Remove the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  4. Remove the heater core. Refer to Heater Core Replacement .
  5. Remove the A/C evaporator lines at the evaporator. Refer to Evaporator Tube Replacement .

    6. Object Number: 416608 Size: SH
  6. Remove the evaporator core cover bolts.
  7. Remove the evaporator core cover.

    8. Object Number: 416610 Size: SH
  8. Remove the evaporator core retaining bolts.
  9. Remove the evaporator core.

    10. Object Number: 416612 Size: SH
  10. Remove the evaporator support strap (1).
  11. Remove the evaporator water core filter retainers (2) and the water core filter (3).

Installation Procedure

    Object Number: 416612 Size: SH
  1. Install the evaporator support strap (1).
  2. Install the evaporator water core filter (3) and the retainers (2).

    3. Object Number: 416610 Size: SH
  3. Install the evaporator.

    4. 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.

  4. Install the evaporator core bolts.

    5. Tighten
    Tighten the evaporator core bolts to 1.5 N·m (13 lb in).


    Object Number: 416608 Size: SH
  5. Install the evaporator core cover.
  6. Install the evaporator core cover bolts.

    7. Tighten
    Tighten the evaporator core cover bolts to 1.5 N·m (13 lb in).

  7. Install the heater core. Refer to Heater Core Replacement .
  8. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  9. Install the A/C evaporator lines at the evaporator. Refer to Evaporator Tube Replacement .
  10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging
  11. Inspect the system for leaks. Refer to Leak Testing .
  12. Install the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L.