GM 52478864
Evaporator Core

The first task to replace the Evaporator core (Delphi) entails removing the hvac module. The hvac module needs heat stakes removal using a screwdriver with hammer before unscrewing the hvac module assembly screws. The Evaporator cowl gasket needs removal from the Evaporator before separating the upper hvac module assembly from the lower hvac module assembly. Detaching the Evaporator core marks the next step for upper hvac module assembly removal. Installation of the Evaporator core requires placing it inside the hvac module assembly after adding refrigerant oil to the core when performing a replacement. Install the Evaporator cowl gasket to the Evaporator after repositioning the upper hvac module assembly to the lower hvac module assembly. Apply screws onto the hvac module assembly before tightening each screw to 2 n.m (18 lb in). Afterward, install the hvac module assembly.

A technician should use the halogen leak detector (J 39400-A) to test for leaks after finishing the core replacement steps along with removing and installing the components. The first step involves disconnecting the underhood lamp electrical connector along with removing the hood and pcm and coolant recovery tank and right front headlamp assembly before progressing to separate the front Bumper and right wheelhouse panel and radio Antenna Cable and electrical horn connector. The next part of the procedure requires removal of the right fender followed by the Blower Motor Resistor then accumulator after which the Evaporator tube must be extracted before unscrewing the mounting bracket for the Evaporator and blower module heat shield and taking off the heat shield while holding onto the mounting bracket for future installation. Use a screwdriver to remove both mounting bolts and nuts from the Evaporator along with the blower module before pulling out the assembled unit from the vehicle. First detach six screws which retain the Evaporator case section to the blower case section and remove the core from the blower case section while testing and replacing necessary seals. Before installing the replacement expansion tube to the Evaporator take out the expansion tube located on the Evaporator. Install the six retaining screws across the blower case section to the Evaporator case section with correct torque at 1.9 n.m (17 lb in). Replace the Evaporator and blower module into the vehicle by attaching its heat shield first and tightening mounting nuts to 4.5 n.m (40 lb in). After tightening the heat shield mounting screws to 2.2 n.m (19 lb in), attach the cooler tubing, collector and accumulator assembly one by one while tightening the Blower Motor Resistor, right fender, horn electrical connector, radio Antenna Cable, right wheelhouse panel, front Bumper, right front headlamp assembly, and electrical connectors for the grille mounted lamps. Pour cooling system reservoir replacement after reinstalling the pcm while also reinstalling all components like hood and underhood lamp electrical connector as you evacuate and recharge the air conditioning system using the halogen leak detector (J 39400-A). Then execution a leak test of all fittings.

The replacement of an Evaporator core requires the halogen leak detector (J 39400-A) as one of the necessary tools. Start by disconnecting the electronic connector of the underhood lamp when present and later remove the hood combined with the pcm and the coolant recovery tank. Detach the lamp electrical connectors from the grille if equipped then take off the right front headlamp assembly, front Bumper along with the right wheelhouse panel. The following steps proceed with radio Antenna Cable and Horn electrical connector removal and subsequent stripping of the right fender along with Blower Motor Resistor, accumulator and Evaporator tube. Disconnect the Evaporator combined with blower module heat shield mounting screws while retaining the heat shield mounting bracket for its reinstallation process. Continued collection includes removal of bolts and nuts holding the Evaporator and blower module before extracting the module from its position in the vehicle. You should remove the Evaporator core by separating the six retaining screws which connect the Evaporator case section to the blower case section. First check and change all necessary seals and next pull out the expansion (orifice) tube from the Evaporator. Position the expansion (orifice) tube on the Evaporator before placing the Evaporator core inside the blower case section and verify the seal alignment. Install six retaining screws through the Evaporator case section to the blower case section while tightening them to 1.9 n.m (17 lb in). Proper installation requires that the bulkhead seal remains in place between the Evaporator and blower module before reinserting the module into the vehicle while fastening mounting screws to 4.5 n.m (40 lb in) torque. The Evaporator and blower module heat shield needs to be installed along with its screws which should get tightened to 2.2 n.m (19 lb in). Next install the Evaporator tube after positioning the accumulator and the Blower Motor Resistor followed by the right fender while reconnecting the Horn electrical connections. First reinstall the radio Antenna Cable and right wheelhouse panel followed by the front Bumper assembly and right front headlamp unit then place the electrical connectors at their positions on the grille-mounted lamps. The last steps involve reinstalling the coolant recovery tank followed by pcm and hood. Additionally the underhood lamp electrical connector needs to be connected if equipped. Then evacuate and recharge the a/c system and check for leaks using the halogen leak detector (J 39400-A).

The replacement process of an Evaporator core starts by obtaining the tools that include the halogen leak detector (J 39400-A). The right fender must be removed first then the Blower Motor Resistor follows and then the accumulator and the Evaporator tube. The next stage entails removing all screws that support the Evaporator and blower module heat shield before extracting the shield. Unscrew the mounting bolts and nuts that secure the Evaporator and blower module then detach them but keep the heat shield mounting bracket safe for future replacement. The extraction process of Evaporator and blower module starts with removing the vehicle components before proceeding to uninstall the six retaining screws that fasten together the Evaporator case section and blower case section for complete separation. Remove the Evaporator core from the blower case section to check the seals which require replacement if needed. The expansion (orifice) tube must be removed from the Evaporator before inserting the new expansion (orifice) tube to the Evaporator assembly. When you are replacing the Evaporator core you should add refrigerant oil to the Evaporator. Put the Evaporator core inside the blower case section before reassembling the Evaporator case section while ensuring the correct placement of its seal between the two parts. Fasten the six retaining screws onto the assembly and tighten them to 1.9 n.m (17 lb in). Reinstall the Evaporator along with the blower module inside the vehicle while making sure the cowl seal maintains its position before tightening the mounting fasteners to 4.5 n.m (40 lb in). Secure the Evaporator and blower module heat shield by screwing it down with torque set at 2.2 n.m (19 lb in). Reinstall all Evaporator tube and accumulator and Blower Motor Resistor followed by right fender installation before performing an a/c system vacuum and recharge operation and performing a leak test on component fittings by using the halogen leak detector (J 39400-A).

Ensure the evaporator and blower module to the bulkhead seal is in place.