GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2001 🢒 Grand Prix 🢒 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. Remove all of the outer HVAC module assembly seals.
  3. Remove the recirculation housing from the HVAC module assembly.
  4. Release the retaining clip to the defroster actuator from the HVAC module assembly.
  5. Remove the defroster actuator.
  6. Remove the HVAC module assembly case upper screws.

    7. Object Number: 295357 Size: SH
  7. Separate the HVAC module assembly case (1).

    8. Object Number: 296253 Size: SH
  8. Remove the HVAC module assembly seal (2) from the lower module case (1).

    9. Object Number: 295362 Size: SH
  9. Remove the evaporator core.

Installation Procedure

    Object Number: 144102 Size: SH
  1. Install the water core filter.

    2. Object Number: 144106 Size: SH
  2. Install a new side seal to the evaporator core.

    3. Object Number: 144104 Size: SH
  3. Install a new upper seal to the evaporator core.

    4. Object Number: 144107 Size: SH
  4. Install 2 new lower seals to the evaporator core.

    5. Object Number: 296253 Size: SH
  5. Install the HVAC module assembly seal (2) to the lower module case (1).

    6. Object Number: 295362 Size: SH
  6. Install the evaporator core into the HVAC module assembly lower case.

    7. Object Number: 295357 Size: SH
  7. Align the guide (1) and attach the lower and upper HVAC module assembly case.

    8. 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.

  8. Install the HVAC module assembly upper screws.

    9. Tighten
    Tighten the HVAC module assembly upper screws to 1.5 N·m (13 lb in).

  9. Install the defroster actuator to the HVAC module assembly.
  10. Install the defroster actuator.
  11. Install the recirculation housing to the HVAC module assembly.

    12. Tighten
    Tighten the recirculation housing screws to 1.5 N·m (13 lb in).

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