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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1125 (Heating, Ventilation And Air Conditioning) >> Repair Instructions >> Evaporator Tube Replacement - Inlet (LY7) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install new sealing washers onto the evaporator inlet tube. Refer to Sealing Washer Replacement .
    2. Fig 1: Evaporator Inlet Tube
    GM651485Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Gently lift up on the evaporator outlet tube bracket to allow enough clearance to slide the evaporator inlet tube underneath.
  2. Install the evaporator inlet tube.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the bracket bolt to the evaporator outlet tube.

    Tighten:  Tighten the bolt to 5.5 N.m (45 lb in).

    4. Fig 2: Identifying Evaporator Inlet Tube From The Condenser & Bolt
    GM825404Courtesy of GENERAL MOTORS CORP.
  4. Remove the cap or tape from the condenser.
  5. Connect the inlet tube to the condenser.
  6. Install the bolt that secures the inlet tube to the condenser.

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

  7. Remove the cap or tape from the TXV.
  8. Connect the inlet tube to the outlet tube.
  9. Connect the outlet tube to the TXV.
    10. Fig 3: View Of Brake Booster
    GM628874Courtesy of GENERAL MOTORS CORP.
  10. Install the outlet tube nut.

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

    11. Fig 4: Locating Evaporator Inlet Tube Clamp Nut
    GM794257Courtesy of GENERAL MOTORS CORP.
  11. Install the inlet tube clamp nut.

    Tighten:  Tighten the nut to 3.3 N.m (29 lb in).

  12. Install the A/C pressure sensor to the inlet tube.

    Tighten:  Tighten the sensor to 5 N.m (44 lb in).

  13. Connect the electrical connector to the A/C pressure sensor.
  14. Install the wiper motor module. Refer to Wiper Motor Module Replacement in Wipers/Washer Systems.
  15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.6L.
  16. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  17. Using J 39400-A  leak test the fittings of the component.
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