GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Conditioning Evaporator Core Replacement

Removal Procedure

    Object Number: 860970 Size: SH
  1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
  2. Remove and discard the cowl panel seals.

    3. Object Number: 860393 Size: SH
  3. Remove the mode valve assembly screws and clips.
  4. Lift the mode valve assembly straight up to remove from the HVAC module.

    5. Object Number: 860430 Size: SH
  5. Remove the upper air inlet case screws and the spring clips.
  6. Lift the upper air inlet case assembly straight up to remove from the lower case assembly.

    7. Object Number: 860434 Size: SH
  7. Remove the evaporator pipe clamp and screw.
  8. Lift the evaporator straight up to remove from the lower case assembly.

Installation Procedure

    Object Number: 860434 Size: SH
  1. Assemble the water filter, the retainers, the evaporator seal and the spacer pad to the new evaporator. Add 67 ml (2.25 oz) of PAG refrigerant oil and replace the evaporator pipe cover.

    2. The evaporator part will come with the filter and pad already installed. 67 ml (2.25 oz) of oil will still have to be added to the evaporator.

  2. Lower the evaporator into the lower case assembly.

    3. Important: Make sure the evaporator pipes are wrapped with mastic on the part being installed.

  3. Install the evaporator pipe clamp and screw.

    4. Object Number: 860427 Size: SH
  4. Place the upper air inlet case on the lower case assembly.

    5. Notice: Make sure all tongue and groove parts fit properly before tightening screws to avoid case damage.

  5. Install the upper air inlet case screws and the spring clips.

    6. Object Number: 860393 Size: SH
  6. Install the mode valve and screws.