GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 L300/LW300 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Conditioning Evaporator Core Replacement

Removal Procedure
  1. Select the following HVAC control settings:
    2. • Ignition in the ON position
    • Recirc to the OFF position
    • Ignition in the OFF position
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Remove the thermal expansion valve (TXV). Refer to Thermal Expansion Valve Replacement .
  4. Remove the instrument panel (I/P) storage compartment. Refer to Instrument Panel Compartment Replacement in Instrument Panel, Gages and Console.

    5. Object Number: 896489 Size: SH
  5. Remove the right side heater duct assembly retainer.
  6. Remove the right side heater duct assembly.

    7. Object Number: 894362 Size: SH
  7. 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.

    8. 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.

  8. 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.

    9. Object Number: 894355 Size: SH
  9. 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.
  10. Carefully clean out any debris that may be inside of the HVAC module.

Installation Procedure
  1. If replacing the evaporator core, add PAG oil to the evaporator. Refer to Refrigerant System Capacities for system capacity information.

    2. Object Number: 894355 Size: SH
  2. Lubricate the evaporator O-rings with mineral oil.
  3. Install the evaporator into the HVAC module.

    4. Use care not to bend the pipes or damage the foam seals.

  4. Inspect the module to TXV foam seal to verify proper location.
  5. Install the TXV. Refer to Thermal Expansion Valve Replacement .

    6. Object Number: 894363 Size: SH

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

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

    7. Object Number: 894354 Size: SH
  7. Install the evaporator core service door to the HVAC module.

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

  8. Install the evaporator core service door screws.

    9. Tighten
    Tighten the screws to 1.0 N·m (9 lb in).

  9. Install the I/P storage compartment. Refer to Instrument Panel Compartment Replacement in Instrument Panel, Gages and Console.

    10. Object Number: 896489 Size: SH
  10. Install the right side heater outlet duct assembly.
  11. Install the right side heater outlet duct assembly retainer.
  12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  13. Select the following HVAC control settings:
    14. • Highest blower speed
    • Mode to the Floor
    • Warmest temperature
    • Recirc to the OFF position
  14. Use the back of your hand to inspect for any air leaks around service door.

    15. If any leaks are found the door must be removed and resealed.

  15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  16. Using the J 39400-A , leak test the fittings of the component.