GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 VUE - FWD 🢒 HVAC 🢒 HVAC - Manual 🢒 Air Conditioning Evaporator Core Replacement

Removal Procedure

    Object Number: 1506432 Size: SH
  1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
  2. Remove the evaporator case assembly. Refer to Air Conditioning (A/C) Evaporator Case Assembly Replacement .
  3. Remove the thermal expansion valve (TXV) bolts from the backing plate.

    4. Object Number: 1506433 Size: SH
  4. Remove the TXV and the backing plate from the evaporator pipes.
  5. Remove the O-rings from evaporator pipes. Refer to O-Ring Replacement .
  6. Install protective caps to the evaporator pipes to prevent system contamination.

    7. Object Number: 1506434 Size: SH
  7. Disconnect the thermal expansion valve (TXV) temperature sensor from the engine harness.
  8. Remove the temperature sensor screw from the evaporator pipe.
  9. Remove the temperature sensor from the evaporator pipe.
  10. Remove the HVAC module front of dash seal.

    11. Object Number: 932990 Size: SH
  11. Remove the evaporator pipe cover screw from the blower case assembly.
  12. Remove the evaporator pipe cover from the blower case assembly.

    13. Object Number: 932971 Size: SH
  13. Remove the evaporator core from the blower case assembly. Spraying the perimeter of the evaporator core seal with a soap and water mixture will ease removal.

Installation Procedure

    Object Number: 932971 Size: SH
  1. Add the proper amount of polyalkylene glycol (PAG) oil to the evaporator core. Refer to Refrigerant System Capacities .
  2. Inspect the seal around the evaporator core. Make sure the seal is in correct position and retained properly.
  3. Spray the seal with a soap and water mixture to ease the installation of evaporator core.
  4. Install the evaporator core to the blower case assembly.

    5. Object Number: 932990 Size: SH
  5. Install the evaporator pipe cover.

    6. Notice: Refer to Fastener Notice in the Preface section.

  6. Install the evaporator pipe cover screw.

    7. Tighten
    Tighten the screw to 1 N·m (9 lb in).


    Object Number: 1506434 Size: SH
  7. Install the HVAC module front of dash seal.

    8. Important: The TXV cavity for temperature sensor must be packed with thermal grease to ensure functionality.

  8. Fill the temperature sensor housing in the TXV with the thermal grease included with the service kit.
  9. Install the temperature sensor and wipe away the excess grease.
  10. Install the temperature sensor screw.

    11. Tighten
    Tighten the screw to 8.5 N·m (75 lb in).

  11. Connect the temperature sensor to the engine harness.

    12. Object Number: 1506433 Size: SH
  12. Remove the protective caps from the evaporator pipes and ensure the seal areas are clean, dry and lint free.

    13. Important: Use only R-12 refrigerant oil (mineral) to lubricate O-rings. Use of R-134a PAG oil will cause premature corrosion of fitting joints.

    Use only clean lint free cloths with non-petroleum based solvents to clean refrigerant system sealing surfaces. Allow solvent to dry with air. Do not allow solvents to enter refrigerant system.

  13. Install new O-rings to the evaporator pipes. Refer to O-Ring Replacement .
  14. Instal the TXV and the backing plate to the evaporator pipes.

    15. Object Number: 1506432 Size: SH
  15. Install the TXV screws to the backing plate.

    16. Tighten
    Tighten the screws to 8 N·m (71 lb in).

  16. Install the evaporator case assembly. Refer to Air Conditioning (A/C) Evaporator Case Assembly Replacement .
  17. Install the HVAC module. Refer to HVAC Module Assembly Replacement .