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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 242 (Heating, Ventilation And Air Conditioning - Gas) >> Repair Instructions >> Evaporator Tube Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the evaporator tube (4).
    Fig 1: Exploded View Of Evaporator Tube
    GM302601Courtesy of GENERAL MOTORS CORP.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the evaporator tube to the evaporator. Use new O-ring seals. Refer to O-Ring Replacement .

    Tighten:  Tighten the fitting to 24 N.m (18 lb ft).

  4. Lower the vehicle.
  5. Install the tube to the retraining clip (6) located on the body side rail (2.4L only).
  6. Install the evaporator tube to the condenser (3). Use the new O-ring seals. Refer to O-Ring Replacement .

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

  7. Install the accumulator tube. Refer to Accumulator Tube Replacement .
    8. Fig 2: Locating Coolant Surge Tank Hoses
    GM631421Courtesy of GENERAL MOTORS CORP.
  8. Install the coolant surge tank hoses to the surge tank.
  9. Use theJ 38185  in order to reposition the hose clamps.
  10. Install the hood close out filler panel. Refer to Hood Close Out Filler Replacement in Body Front End.
  11. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging .
  12. Leak test the fittings of the component using the J 39400-A  .
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