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For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Aztek - AWD 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Conditioning Evaporator Tube Replacement - Inlet

Air Conditioning Evaporator Tube Replacement - Inlet LA1

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -3.4L.
  2. Disconnect the cruise control module electrical connector.
  3. Reposition the cruise control module aside.

    4. Object Number: 826649 Size: SH
  4. Remove the cruise control module mounting bracket bolts.
  5. Remove the cruise control module mounting bracket.
  6. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
  7. Remove the wiper motor module. Refer to Windshield Wiper System Module Replacement in Wipers/Washer Systems.

    8. Object Number: 794257 Size: SH
  8. Remove the evaporator inlet tube clamp nut.
  9. Disconnect the electrical connector from the A/C pressure sensor.
  10. Remove the A/C pressure sensor from the evaporator inlet tube.

    11. Object Number: 628874 Size: SH
  11. Remove the evaporator outlet tube to TXV nut.
  12. Disconnect the evaporator outlet tube from the TXV.
  13. Disconnect the evaporator inlet tube from the evaporator outlet tube.

    14. Important: Cap or tape the A/C refrigerant components immediately to prevent system contamination.

  14. Cap or tape off the TXV.

    15. Object Number: 825404 Size: SH
  15. Remove the evaporator inlet tube to condenser fitting bolt.
  16. Disconnect the evaporator inlet tube from the condenser.
  17. Cap or tape off the condenser.
  18. Remove the evaporator outlet tube bracket bolt.

    19. Object Number: 651485 Size: SH

    Important: Gently lift up on the evaporator outlet tube bracket to allow enough clearance to slide the evaporator inlet tube underneath.

  19. Remove the evaporator inlet tube.
  20. Remove and discard the sealing washers.

Installation Procedure
  1. Install new sealing washers onto the evaporator inlet tube. Refer to Sealing Washer Replacement .

    2. Important: Gently lift up on the evaporator outlet tube bracket to allow enough clearance to slide the evaporator inlet tube underneath.


    Object Number: 651485 Size: SH
  2. Install the evaporator inlet tube.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the evaporator outlet tube bracket bolt.

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


    Object Number: 825404 Size: SH
  4. Remove the cap or tape from the condenser.
  5. Connect the evaporator inlet tube to the condenser.
  6. Install the evaporator inlet tube to condenser bolt.

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

  7. Remove the cap or tape from the TXV.
  8. Connect the evaporator inlet tube to the evaporator outlet tube.
  9. Connect the evaporator outlet tube to the TXV.

    10. Object Number: 628874 Size: SH
  10. Install the evaporator outlet tube nut.

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


    Object Number: 794257 Size: SH
  11. Install the evaporator inlet tube clamp nut.

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

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

    13. 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 Windshield Wiper System Module Replacement in Wipers/Washer Systems.
  15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -3.4L.

    16. Object Number: 826649 Size: SH
  16. Install the cruise control module mounting bracket.
  17. Install the cruise control module mounting bracket bolts.

    18. Tighten
    Tighten the bolts to 6 N·m (53 lb in).

  18. Install the cruise control module into the mounting bracket.
  19. Connect the cruise control module electrical connector.
  20. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  21. Leak test the fittings of the component using J 39400-A .

Air Conditioning Evaporator Tube Replacement - Inlet LY7

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.6L.
  2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
  3. Remove the wiper motor module. Refer to Windshield Wiper System Module Replacement in Wipers/Washer Systems.

    4. Object Number: 794257 Size: SH
  4. Remove the clamp nut from the evaporator inlet tube.
  5. Disconnect the electrical connector from the A/C pressure sensor.
  6. Remove the A/C pressure sensor from the evaporator inlet tube.

    7. Object Number: 628874 Size: SH
  7. Remove the nut that secures the evaporator outlet tube to the TXV.
  8. Disconnect the evaporator outlet tube from the TXV.
  9. Disconnect the evaporator inlet tube from the evaporator outlet tube.

    10. Important: Cap or tape the A/C refrigerant components immediately to prevent system contamination.

  10. Cap or tape off the TXV.

    11. Object Number: 825404 Size: SH
  11. Remove the bolt that secures the evaporator inlet tube to the condenser fitting.
  12. Disconnect the evaporator inlet tube from the condenser.
  13. Cap or tape off the condenser.

    14. Object Number: 651485 Size: SH
  14. Remove the bracket bolt from the evaporator outlet tube.

    15. Important: Gently lift up on the evaporator outlet tube bracket to allow enough clearance to slide the evaporator inlet tube underneath.

  15. Remove the evaporator inlet tube.
  16. Remove and discard the sealing washers.

Installation Procedure
  1. Install new sealing washers onto the evaporator inlet tube. Refer to Sealing Washer Replacement .

    2. Object Number: 651485 Size: SH

    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. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the bracket bolt to the evaporator outlet tube.

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


    Object Number: 825404 Size: SH
  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.

    7. 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. Object Number: 628874 Size: SH
  10. Install the outlet tube nut.

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


    Object Number: 794257 Size: SH
  11. Install the inlet tube clamp nut.

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

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

    13. 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 Windshield Wiper System 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.