GM Storm/Spectrum 1985-1993 Repair Guide

Evaporator Core

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REMOVAL & INSTALLATION



Spectrum
  1. Disconnect the negative battery cable and properly discharge the refrigerant system.
  2.  
  3. Remove the insulator at outlet of the evaporator and blower joint. Remove the thermo switch from the upper case.
  4.  
  5. Remove the clips retaining the upper and lower halves of the evaporator case, then remove the upper half.
  6.  
  7. Carefully pull the thermo-switch capillary tube from the evaporator core. Remove the thermo-switch.
  8.  
  9. Remove the evaporator core along with the expansion valve, leaving the inlet and outlet lines attached.
  10.  
  11. Peel the insulation tape from the thermo bulb expansion valve and the equalizer line connection.
  12.  
  13. Disconnect the expansion valve intake pipe connection, the equalizer line and the evaporator outlet line and remove the core. Cap or plug all open connections at once.
  14.  

To install:

Lubricate the line fittings with clean refrigeration oil prior to installation.

  1. Install the core. Add 1.7 fluid oz. (50 ml) of new refrigeration oil to a new core. Connect the expansion valve intake pipe connection, the equalizer line and the evaporator outlet line.
  2.  
  3. With fresh insulation tape, tape the thermo bulb expansion valve and the equalizer line connection.
  4.  
  5. Install the evaporator core with the expansion valve.
  6.  
  7. Install the thermo-switch capillary tube to the evaporator core.
  8.  
  9. Install the upper half of the evaporator case and install the clips retaining the upper and lower halves.
  10.  
  11. Connect the thermo-switch to the upper case.
  12.  
  13. Install the insulator at the outlet of the evaporator and blower joint.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Evacuate, charge and check the operation of the system.
  18.  

Storm
  1. Disconnect the negative battery cable and properly discharge the refrigerant system.
  2.  
  3. Disconnect the lines from the expansion valve.
  4.  
  5. Remove the retaining clip and the expansion valve from the evaporator.
  6.  
  7. Remove the glove box from the instrument panel.
  8.  
  9. Remove the lower instrument panel reinforcement bracket.
  10.  
  11. Disconnect the electrical connectors from the thermostatic switch and the blower motor resistor.
  12.  
  13. Disconnect the air inlet cable from the blend door.
  14.  
  15. Remove the retaining nuts from the evaporator case.
  16.  
  17. Remove the evaporator case from the instrument panel.
  18.  
  19. Remove the retaining clips from the evaporator case.
  20.  
  21. Remove the four case screws.
  22.  
  23. Remove the case halves.
  24.  
  25. Remove the evaporator core from the case.
  26.  

To install:
  1. Install the evaporator core into the case.
  2.  
  3. Install the case halves and tighten the four screws.
  4.  
  5. Install the retaining clips.
  6.  
  7. Install the evaporator case into the instrument panel and tighten the retaining nuts.
  8.  
  9. Connect the air inlet cable to the blend door.
  10.  
  11. Connect the electrical connectors to the thermostatic switch and the blower motor resistor.
  12.  
  13. Install the lower instrument panel reinforcement bracket.
  14.  
  15. Install the glove box into the instrument panel.
  16.  
  17. Install the expansion valve to the evaporator and install the retaining clip.
  18.  
  19. Connect the lines to the expansion valve.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Evacuate, charge and check the operation of the system.
  24.  

 
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