GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2001 🢒 L100/L200/LW200 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Conditioning Evaporator Core Replacement

Removal Procedure

    Object Number: 878122 Size: SH
  1. Turn ignition ON and select outside air on control head.
  2. Disconnect the negative battery cable.
  3. Remove the thermal expansion valve (TXV). Refer to Thermal Expansion Valve (TXV) removal procedure in this service manual.

    4. Object Number: 896875 Size: SH
  4. Open the glove compartment door.
  5. Remove the glove compartment lamp assembly by pulling on the lamp plunger.
  6. Disconnect the glove compartment lamp wiring harness from the glove compartment lamp.

    7. Object Number: 896491 Size: SH
  7. Remove the right side I/P lower dash insulator retainers.
  8. Pull the insulator rearward to detach the insulator from the forward insulator support.
  9. Remove the insulator support from the front of the dash studs by pulling the insulator rearward.

    10. Object Number: 896489 Size: SH
  10. Remove the right side heater duct assembly retainer and remove the duct.

    11. Object Number: 896834 Size: SH
  11. Remove the glove compartment door.

    12. Object Number: 896914 Size: SH
  12. Remove the glove compartment bin fasteners.
  13. Slowly remove the glove compartment bin, tilting the bin downward to expose the body control module (BCM) module residing on top of the glove compartment.
  14. Remove the BCM module from the glove compartment by sliding the module out of the attaching slots.
  15. Remove glove compartment bin.

    16. Object Number: 894362 Size: SH
  16. Locate the evaporator access door location on the right side of the module. The entire area inside the raised lip is to be cut out.

    17. Object Number: 894353 Size: SH

    Notice: To avoid cutting internal components, cut only inside raised bead area.

    Important: Do not cut through or damage the raised bead, this bead will be used as a sealing surface when completing the procedure.

  17. Using a sharp utility knife, cut through the module wall, following inside of the raised bead as a guide. Several passes may be necessary to accomplish this.

    18. Object Number: 894355 Size: SH
  18. From the inside of the vehicle, slide the evaporator core out through the access door opening. Use care not to damage the core fins or pipes. Install caps on the pipes to prevent oil spillage.
  19. Carefully clean out any debris that may be inside of the module.

Installation Procedure

    Object Number: 894355 Size: SH

    Important: Add 72 ml (2.4 oz) of PAG oil to the new evaporator.

  1. Lubricate the evaporator O-rings with mineral oil.
  2. Install the evaporator into the module. Use care not to bend the pipes or damage the foam seals.
  3. Inspect module/TXV foam seal to verify proper location.
  4. Install the thermal expansion valve (TXV). Refer to Thermal Expansion Valve Replacement .

    5. Object Number: 894363 Size: SH

    Notice: Proper sealing is important to prevent condensation from leaking into the passenger compartment.

  5. Apply the provided sealant to the service door at the tongue and groove location as shown.

    6. Object Number: 894354 Size: SH
  6. Install the evaporator core service door to the module and install the screws.

    7. Tighten
    Tighten the evaporator core service door-to-HVAC module fasteners to 1.0 N·m (9 lb in).


    Object Number: 896914 Size: SH
  7. Install the glove compartment bin partially into the opening.
  8. Secure the BCM module to the glove compartment bin slots.
  9. Route the glove compartment lamp wiring harness through the lamp opening.
  10. Install the glove compartment bin to the I/P with the fasteners.

    11. Tighten
    Tighten the glove compartment bin-to-I/P fasteners to 2.5 N·m (22 lb in).


    Object Number: 896875 Size: SH
  11. Connect the glove compartment lamp wiring harness to the glove compartment lamp.
  12. Snap the lamp into the glove compartment bin.

    13. Object Number: 896489 Size: SH
  13. Install the heater outlet with the retainer.

    14. Object Number: 896491 Size: SH
  14. Install the lower dash insulator support.
  15. Install the lower dash insulator with the retainers.

    16. Object Number: 896834 Size: SH
  16. Install the glove compartment door with the fasteners.

    17. Tighten
    Tighten the glove compartment door fasteners to 2.0 N·m (18 lb in).

  17. Function the glove compartment lamp and glove compartment door to ensure proper operation.

    18. Object Number: 878122 Size: SH
  18. Connect the negative battery cable.

    19. Tighten
    Tighten the battery terminal bolts to 17 N·m (13 lb ft).

  19. Evacuate, charge, and leak check the A/C system.
  20. Turn HVAC blower ON with mode set to heater, temperature on hot, recirc on outside air.
  21. Use the back of your hand to check for any air leaks around service door. If any leaks are found the door must be removed and resealed.