How to uninstall and replace AC evaporator and what fluids I will need

Remove or Disconnect

Discharge refrigerant into a recovery station.
Right-hand instrument panel sound insulator panel.
Heater hoses at heater core.
Instrument panel compartment.
Heater Core.
Air conditioning evaporator temperature sensor.
Temperature control cable at temperature valve case.
Bolts/screws (48) located in engine compartment from temperature valve case (42).
Temperature valve case (42).

Slide case (42) downward to disengage upper case clip.
Remove from under the instrument panel.

Thermostatic expansion valve.

Important

Remove perforated section of heater and air conditioning evaporator module as one piece (it will be reused).
Water can leak onto carpeting when doing this procedure. It is recommended that a mat be placed on passenger side floor.

Using a small hand saw, remove perforated section of heater and air conditioning evaporator module.

Important

This piece of material is required to keep condensate from draining inside vehicle.

Bolts/screws (41) retaining air conditioning evaporator (3).
Air conditioning evaporator (3) from heater and air conditioning module (11).

Slide evaporator (3) to the left, then pull out through the opening enlarged in step 11.

Install or Connect

Transfer condensate screen to new evaporator (3).
Install new evaporator core gasket in same position as original with appropriate adhesive.
Air conditioning evaporator (3) to heater and air conditioning module (11).

Insert evaporator (3) into module (It) through the opening enlarged during removal, slide to the right until fully seated.

Bolts/screws (41) to air conditioning evaporator (3).
Thermostatic expansion valve.
Apply sealer GM P/N 3012078 (do not use epoxy glue) between evaporator (3) and evaporator upper and lower case (44 and 45) just behind thermostatic expansion valve to prevent air entry from the engine compartment into the passenger compartment.
Position perforated section of heater and air conditioning evaporator module and use epoxy glue to adhere it to module. After epoxy dries, use thumb to grade sealant on inside and outside to ensure water-tight seal.
Temperature valve case (42).

Install from under instrument panel.
Slide case (42) upward into position until upper clip engages.
Engage snap on left edge of temperature valve case (42) to distributor case (46).

Bolts/screws (48) to temperature valve case (42).
Temperature control cable at temperature valve case.
Air conditioning evaporator temperature sensor.
Heater core.
Instrument panel compartment.
Heater hoses to heater core.
Right-hand instrument panel sound insulator panel.
Fill radiator and bleed cooling system.
Refrigerant oil into evaporator (3), if necessary.

If installing new evaporator (3), add 89 ml (3 fluid ounces) of polyalkylene glycol (PAG) synthetic refrigerant oil, GM P/N 12345923.

Tighten

Bolts/screws (48) evenly to compress flange seal.

Add 2 ounces of oil to the evap before installation. Replace the dryer as well, evacuate it well and then charge it

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