GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 2006 🢒 Rendezvous - FWD 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Conditioning Evaporator Tube Replacement - Inlet

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 3.5L engine or Air Cleaner Assembly Replacement for the 3.6L engine.
  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 .

    4. Object Number: 794257 Size: SH
  4. Remove the evaporator inlet tube clamp nut.
  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 evaporator outlet tube to thermal expansion valve (TXV) nut.
  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 evaporator inlet tube to condenser fitting bolt.
  12. Disconnect the evaporator inlet tube from the condenser.
  13. Cap or tape off the condenser.
  14. Remove the evaporator outlet tube bracket bolt.

    15. 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.

  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 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 .
  15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 3.5L engine or Air Cleaner Assembly Replacement for the 3.6L engine.
  16. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  17. Leak test the fittings of the component using J 39400-A .