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Removal 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. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
  3. Remove the brake pressure modulator (BPMV) valve bracket. Refer to Brake Pressure Modulator Valve (BPMV) Bracket Replacement in Anti-lock Brake System.
  4. Disconnect the electrical connector from the brake fluid level sensor.
  5. Remove the master cylinder mounting nuts.
  6. Remove the master cylinder from the brake booster and position aside.
  7. Remove the engine vacuum line from the brake booster.
    8. Fig 1: Removing A/C Line Coupling & Dehydrator Mounting Bolt
    GM1204147Courtesy of GENERAL MOTORS CORP.
  8. Remove the A/C line coupling from the evaporator tube to receiver dehydrator tube (1). Refer to A/C Line/Tube Connector Removal/Replacement .
  9. Remove the receiver dehydrator mounting bolt (2).
  10. Disconnect the receiver dehydrator from the evaporator tube.
  11. Remove the block fitting nut that secures the evaporator tube to the A/C compressor hose assembly.
  12. Disconnect the evaporator tube from the A/C compressor hose assembly.
    13. Fig 2: Block Fitting Nut
    GM1118015Courtesy of GENERAL MOTORS CORP.
  13. Remove the block fitting nut (1) that secures the evaporator tube to the thermal expansion valve (TXV).
  14. Remove the heater hoses from the support bracket and position aside.
  15. Remove the transmission shifter cable from the retainer above the heater hoses and position the cable aside.
  16. Disconnect the evaporator tube from the TXV.
    17. Fig 3: Evaporator Tube & Support Clip
    GM1236125Courtesy of GENERAL MOTORS CORP.
  17. Remove the evaporator tube from the support clip (1) on the left fender rail.
  18. Remove the transaxle fluid filler tube. Refer to Fluid Filler Tube Replacement in Automatic Transaxle - 4T65-E.
  19. Disconnect the wire harness electrical connector on the top of the left shock tower.
  20. Disconnect the wire harness electrical connector from the A/C pressure sensor.
  21. Remove the evaporator tube from the vehicle.
    22. Fig 4: A/C Refrigerant Pressure Sensor
    GM282279Courtesy of GENERAL MOTORS CORP.
  22. Remove the A/C pressure sensor.
  23. Remove and discard the O-ring seals and seal washers.
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