GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Avalanche - 2WD 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Evaporator Tube Replacement

Evaporator Tube Replacement Non HP2

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the upper radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement .
  3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  4. Remove the surge tank hold down nut and bolt and position aside.

    5. Important: Do not open cooling system.


    Object Number: 385463 Size: SH
  5. Remove the evaporator tube nut from the evaporator.
  6. Disconnect the evaporator tube from the evaporator.
  7. Remove the evaporator tube nut from the auxiliary A/C tube, if equipped.
  8. Disconnect the evaporator tube from the auxiliary A/C tube, if equipped.

    9. Object Number: 363033 Size: SH
  9. Remove the evaporator tube nut from the condenser.
  10. Disconnect the evaporator tube from the condenser.
  11. Remove the evaporator tube from the vehicle.
  12. Discard all of the used sealing washers. Cap all of the open connections.

Installation Procedure
  1. Connect the evaporator tube to the condenser using new sealing washers. Refer to Sealing Washer Replacement .

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


    Object Number: 363033 Size: SH
  2. Install the evaporator tube nut to the condenser.

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

  3. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers, if equipped. Refer to Sealing Washer Replacement .
  4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped.

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

  5. Install the evaporator tube to the evaporator.

    6. Object Number: 385463 Size: SH
  6. Install the evaporator tube nut to the evaporator.

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

  7. Install the surge tank hold down nut and bolt and position aside.
  8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  9. Install the upper radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement .
  10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging .
  11. Leak test the fittings of the components using the J 39400-A .

Evaporator Tube Replacement W/O C69 HP2


Object Number: 1965664 Size: MF

Callout

Component Name

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

   • Identify how to disable high voltage.
   • Identify how to test for the presence of high voltage.
   • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Failure to follow the procedures exactly as written may result in serious injury or death.

Preliminary Procedures

  1. Disable the hybrid high voltage system. Refer to High Voltage Disabling .
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging and High Voltage Enabling .
  3. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
  4. Remove air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  6. Remove the right front wheelhouse lining. Refer to Front Wheelhouse Liner Replacement - Right Side
  7. Remove the radiator air upper baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
  8. Remove the engine shield. Refer to Engine Shield Replacement .
  9. Remove the oil pan skid plate. Refer to Oil Pan Skid Plate Replacement .

1

Evaporator Tube to TXV Nut

Notice: Refer to Fastener Notice in the Preface section.

Tighten
16 N·m (12 lb ft)

2

Evaporator Tube to Condenser Nut

Tighten
16 N·m (12 lb ft)

3

Evaporator Tube

Procedure

  1. Undo coupling and remove through wheelhouse opening.
  2. Remove and discard sealing washer. Refer to Sealing Washer Replacement .
  3. Enable the hybrid high voltage system. Refer to High Voltage Enabling .

Evaporator Tube Replacement W/C69 HP2


Object Number: 1965662 Size: MF

Callout

Component Name

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

   • Identify how to disable high voltage.
   • Identify how to test for the presence of high voltage.
   • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Failure to follow the procedures exactly as written may result in serious injury or death.

Preliminary Procedures

  1. Disable the hybrid high voltage system. Refer to High Voltage Disabling .
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging and High Voltage Enabling .
  3. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
  4. Remove air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  6. Remove the right front wheelhouse lining. Refer to Front Wheelhouse Liner Replacement - Right Side
  7. Remove the radiator air upper baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
  8. Remove the engine shield. Refer to Engine Shield Replacement .
  9. Remove the oil pan skid plate. Refer to Oil Pan Skid Plate Replacement .

1

Evaporator Tube to TXV Nut

Notice: Refer to Fastener Notice in the Preface section.

Tip
Discard all of the used sealing washers.

Tighten
16 N·m (12 lb ft)

2

Evaporator Tube to Condenser Nut.

Tighten
16 N·m (12 lb ft)

3

Evaporator Tube to Rear A/C Nut

Tighten
16 N·m (12 lb ft)

4

Evaporator Tube

Procedure

  1. Undo coupling and remove through wheelhouse opening.
  2. Remove and discard sealing washer. Refer to Sealing Washer Replacement .
  3. Enable the hybrid high voltage system. Refer to High Voltage Enabling .