Chevrolet Cobalt Service & Repair Manual: Evaporator Core, Replace

Chevrolet Cobalt Service & Repair Manual / Air Conditioning & Heater / Component Replacement & Adjustment / Evaporator Core, Replace

The defroster door must be closed to allow clearance during defroster duct removal.
1. Evacuate system as outlined under "Refrigerant Recovery" in "General Service" on main menu selection.
2. Remove surge tank cap.
3. Drain engine coolant into a suitable container.
4. Set Heating, Ventilation and Air Conditioning (HVAC) controls in vent setting to close defroster door.
5. Remove right side instrument panel insulator.
6. Reposition heater outlet hose clamp at heater core.
7. Position hose upright against front of dash.
8. Remove condenser tube and evaporator hose from Thermal Expansion Valve (TXV).
9. Raise center floor outlet duct while pushing floor ducts down to disengage ducts.
10. Rotate center floor outlet duct forward in vehicle and pull down to disengage duct from HVAC module.
11. Disconnect blower motor electrical connector.
12. Remove instrument panel (I/P) carrier.
13. Remove wire harness rosebuds from lefthand side of beam.
14. Remove wire harness rosebuds from lefthand side of steering column support bracket.
15. Remove metal clip from steering column support bracket.
16. Remove wire harness rosebuds from righthand side of steering column support bracket.
17. Unsnap defroster duct from HVAC module and beam. Bend cluster wire harness tab on I/P carrier to remove defroster duct.
18. Remove cluster wire harness rosebuds from I/P carrier.
19. Remove stop lamp switch from brake pedal bracket.
20. Remove cruise control release switch from brake pedal bracket.
21. If equipped with a manual transmission, remove clutch switch from clutch pedal bracket.
22. Remove I/P wire harness ground wires from steering column support bracket.
23. Disconnect electrical connectors from electric power steering motor.
24. Remove electric power steering power wire rosebuds from steering column support bracket.
25. Remove wire harness rosebuds from center of HVAC module.
26. Remove wire harness rosebuds from righthand side of I/P carrier.
27. Remove HVAC module nuts at front of dash.
28. Remove HVAC module nuts at I/P carrier.
29. Remove steering column pivot bolt and rest steering column on floor pan.
30. If equipped with a manual transmission, remove clutch pedal nut. Position clutch pedal bracket away from I/P carrier.
31. Remove lefthand steering column support bracket to front of dash nuts.
32. Remove center steering column support bracket nuts.
33. Remove brake pedal bracket to steering column support bracket bolt.
34. Remove righthand and lefthand I/P carrier to vehicle bolts.
35. Slide I/P carrier rearward, disconnect HVAC module from I/P carrier, and remove I/P carrier from vehicle.
36. Remove heater core cover screws and cover.
37. Remove heater core.
38. Unsnap and open passenger compartment filter door.
39. Remove lower HVAC case screws, Fig. 1.
40. Remove lower HVAC case, Fig. 2.
41. Remove evaporator core.
42. Reverse procedure to install, noting the following:
  a. Torque blower motor screws to 16 inch lbs.
  b. Torque evaporator outlet line to TXV nut to 15 ft. lbs.
  c. Torque evaporator core mounting bolts to 62 inch lbs.
  d. Torque Instrument Panel (I/P) carrier bolts to 18 ft. lbs.
  e. Torque heater core cover screws to 16 inch lbs.

Fig. 1 HVAC case screws

Fig. 2 Lower case separated

    Clutch, Replace
    1. Evacuate system as outlined under "Refrigerant Recovery" in "General Service" on main menu selection. 2. Raise and ...

    Expansion Valve (TXV), Replace
    1. Evacuate system as outlined under "Refrigerant Recovery" in "General Service" on main menu selection. 2. Repositio ...

    See also:

    Chevrolet Cobalt Owners Manual. Collision Damage Repair
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    Chevrolet Cobalt Owners Manual

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