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

Removal Procedure

    Object Number: 604127 Size: SH
  1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .
  2. Remove the heater core case shroud.
  3. Remove the heater core bracket and screw.
  4. Remove the heater core .

    5. Object Number: 604130 Size: SH
  5. Remove the screw and evaporator core bracket.
  6. Remove the evaporator core.

Installation Procedure

    Notice: Do not mix refrigerant oils. Use of incorrect refrigerant oil will cause compressor failure.

    The CVC compressor uses a low viscosity refrigerant oil, GM P/N 12378526 (Canadian P/N 88900060).

    Important: If you are installing a new evaporator core add the proper quantity of refrigerant oil to the evaporator core. Refer to Refrigerant System Capacities .

  1. Install the evaporator core.

    2. 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.

  2. Install the evaporator core bracket and screws.

    3. Tighten
    Tighten the screws to 1 N·m (9 lb in).


    Object Number: 604127 Size: SH
  3. Install the heater core
  4. Install the heater core bracket and screw.
  5. Install the heater core case shroud screws.

    6. Tighten
    Tighten the screws to 1 N·m (9 lb in).

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