GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2000 🢒 Grand Prix 🢒 Body and Accessories 🢒 Waterleaks 🢒 Air Conditioning Evaporator Core Replacement

Removal Procedure
  1. Remove the HVAC control module. Refer to HVAC Module Assembly Replacement .
  2. Remove all of the outer HVAC control module seals.
  3. Remove the air inlet housing.
  4. Release the retaining clip to the heater/defrost valve vacuum actuator from the HVAC control module.
  5. Remove the heater/defrost valve vacuum actuator.
  6. Remove the HVAC control module case upper screws.

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

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

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

    10. Object Number: 144107 Size: SH
  10. Remove and discard the evaporator core lower seals.

    11. Object Number: 144104 Size: SH
  11. Remove and discard the evaporator core upper seal.

    12. Object Number: 144106 Size: SH
  12. Remove and discard the evaporator core side seal.

    13. Object Number: 144102 Size: SH
  13. Remove and discard the water core filter.

Installation Procedure

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

    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 two new lower seals to the evaporator core.

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

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

    7. Object Number: 295357 Size: SH
  7. Align the retaining clip (1) and install the upper and lower HVAC mode 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 control module case upper screws.

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

  9. Install the heater/defrost valve vacuum modulator.
  10. Install the retaining clip for the heater/defrost valve vacuum actuator to the HVAC control module.
  11. Install the air inlet housing.

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

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