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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 982 (Heating, Ventilation And Air Conditioning - Gas) >> Repair Instructions >> Evaporator Tube Replacement (W/ HP2) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the front evaporator tube to the vehicle.
    Fig 1: Installing Front Evaporator Tube To Vehicle (W/ HP2)
    GM1336348Courtesy of GENERAL MOTORS CORP.
  2. Uncap all of the open connections
  3. Install the evaporator tube to the condenser using new sealing washers. Refer to Sealing Washer Replacement .
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
    Fig 2: Installing Evaporator Tube To Condenser (W/ HP2)
    GM363033Courtesy of GENERAL MOTORS CORP.
  4. Install the evaporator tube nut to the condenser.

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

  5. Install the grille to the vehicle. Refer to Grille Replacement (GMC) or Grille Replacement (Chevrolet) .
  6. Install the right park/turn signal lamp. Refer to Park/Turn Signal Lamp Replacement (Old Style) .
    7. Fig 3: Installing SGCM Coolant Pump (W/ HP2)
    GM1206679Courtesy of GENERAL MOTORS CORP.
  7. Position the SGCM coolant pump (1) to the radiator core support (3).
  8. Install the bolts (2) to the SGCM coolant pump (1).

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

  9. Install the push pin to the right side radiator air baffle.
  10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 5.3L.
  11. Install the rear evaporator tube (3) to the vehicle.
    Fig 4: Locating Evaporator Tube
    GM703266Courtesy of GENERAL MOTORS CORP.
  12. Connect the nut to the evaporator tube fitting.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

  13. Install the evaporator tube to the evaporator.
    14. Fig 5: Removing/Installling Evaporator Tube At Evaporator
    GM385463Courtesy of GENERAL MOTORS CORP.
  14. Install the evaporator tube nut to the evaporator.

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

  15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  16. Leak test the fittings of the components using the J 39400-A  . See Special Tools and Equipment .
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