GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Vibe - AWD 🢒 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. Object Number: 834618 Size: SH
  2. Remove the 4 bolts (1) and the 2 air ducts (2).

    3. Object Number: 834626 Size: SH
  3. Remove the 2 bolts (2) and the air outlet lever (1).
  4. Remove the 4 bolts and the blower motor upper case.

    5. Object Number: 834635 Size: SH
  5. Remove the bolts and the evaporator case cover.
  6. Remove the evaporator.
  7. Remove the 2 bolts and expansion valve from the evaporator.

Installation Procedure

    Important: If the evaporator was replaced add 60 ml (2.0 fl oz) of compressor oil.

    Install new O-rings lubricated with 525 viscosity mineral oil.

    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.

  1. Install the expansion valve to the evaporator. Secure with the 2 bolts.

    2. Tighten
    Tighten the bolts to 5.4 N·m (48 lb in).

  2. Install the evaporator to the HVAC module assembly

    3. Object Number: 834635 Size: SH
  3. Install the evaporator case cover to the HVAC module assembly. Secure with the bolts.

    4. Tighten
    Tighten the bolts to 10N·m (89 lb in).

  4. Install the 4 bolts and the blower motor upper case.

    5. Tighten
    Tighten the bolts to 10N·m (89 lb in).


    Object Number: 834626 Size: SH
  5. Install the air outlet lever (1). Secure the lever with the 2 bolts (2).

    6. Tighten
    Tighten the bolts (2) to 10N·m (89 lb in).


    Object Number: 834618 Size: SH
  6. Install the 2 air ducts (2). Secure the air ducts with the 4 bolts (1).

    7. Tighten
    Tighten the bolts (1) to 10N·m (89 lb in).

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