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Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Replace the O-ring seals on the receiver dehydrator and A/C pressure sensor. Refer to O-Ring Replacement .
    2. Fig 1: A/C Refrigerant Pressure Sensor
    GM282279Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the A/C refrigerant pressure sensor.

    Tighten:  Tighten the sensor to 4.7 N.m (41 lb in).

  3. Replace the seal washers on the evaporator tube. Refer to Sealing Washer Replacement .
  4. Install the evaporator tube to the vehicle.
    5. Fig 2: Evaporator Tube & Support Clip
    GM1236125Courtesy of GENERAL MOTORS CORP.
  5. Connect the evaporator tube to the support clip (1).
  6. Install the evaporator tube to the TXV.
    7. Fig 3: Block Fitting Nut
    GM1118015Courtesy of GENERAL MOTORS CORP.
  7. Install the evaporator tube to TXV nut (1).

    Tighten:  Tighten the nut to 27 N.m (20 lb ft).

  8. Install the transaxle fluid filler tube. Refer to Fluid Filler Tube Replacement in Automatic Transaxle - 4T65-E.
  9. Install the heater hoses to the support bracket.
  10. Install the transmission shifter cable to the retainer above the heater hoses.
  11. Connect the receiver dehydrator to the evaporator tube.
    12. Fig 4: Removing A/C Line Coupling & Dehydrator Mounting Bolt
    GM1204147Courtesy of GENERAL MOTORS CORP.
  12. Install the A/C line coupling to the evaporator tube and receiver dehydrator tube (1). Refer to A/C Line/Tube Connector Removal/Replacement .
  13. Install the receiver dehydrator mounting bolt (2).

    Tighten:  Tighten the bolt to 10 N.m (88 lb in).

  14. Connect the A/C compressor hose assembly to the evaporator tube.
  15. Install the A/C compressor hose assembly to evaporator tube block fitting nut.

    Tighten:  Tighten the nut to 16 N.m (12 lb ft).

  16. Install the BPMV bracket. Refer to Brake Pressure Modulator Valve (BPMV) Bracket Replacement in Anti-lock Brake System.
  17. Install the master cylinder to the brake booster.
  18. Install the nuts to the master cylinder.

    Tighten:  Tighten the nuts to 25 N.m (18 lb ft).

  19. Connect the electrical connector to the brake fluid level sensor.
  20. Install the engine vacuum line to the brake booster.
  21. Connect the wire harness electrical connector on the top of the left shock tower.
  22. Connect the electrical connector to the A/C refrigerant pressure sensor.
  23. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
  24. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  25. Leak test the fittings of the component using J 39400-A .
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