GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Express - AWD 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Air Conditioning Evaporator Core Replacement

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
  2. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.

    3. Object Number: 924798 Size: SH
  3. Disconnect the low pressure sensor electrical connector (2).

    4. Object Number: 1190441 Size: SH
  4. Disconnect the blower motor assembly electrical connector.

    5. Object Number: 1190432 Size: SH
  5. Disconnect the blower motor resistor assembly electrical connector.

    6. Object Number: 1190579 Size: SH
  6. Remove the retaining nut (1) from the evaporator inlet tube.
  7. Remove the evaporator inlet tube retaining screw.
  8. Remove the evaporator inlet tube from the evaporator.
  9. Remove the O-ring seal.

    10. Object Number: 924801 Size: SH
  10. Remove the retaining nut (1) from the accumulator.
  11. Remove the accumulator from the evaporator.
  12. Remove the O-ring seal.

    13. Object Number: 1190546 Size: SH
  13. Remove the blower module assembly screws.
  14. Remove the blower module assembly.
  15. Remove the evaporator core from the evaporator and blower module assembly.

Installation Procedure
  1. If replacing the evaporator core, add the specified amount of PAG oil directly into the evaporator. Refer to Refrigerant System Capacities.

    2. Object Number: 1190572 Size: SH
  2. Install the evaporator.

    3. Object Number: 1190546 Size: SH
  3. Install the evaporator and blower module assembly.
  4. Install the evaporator and blower module assembly retaining screws.
  5. Install new O-ring seals. Refer to O-Ring Replacement.

    6. Object Number: 924801 Size: SH
  6. Install the accumulator to the evaporator.

    7. Caution: Refer to Fastener Caution in the Preface section.

  7. Install the accumulator retaining nut (1) and tighten to 18 N·m (13 lb ft).
  8. Install the evaporator inlet tube to the evaporator.

    9. Object Number: 1190579 Size: SH
  9. Install the evaporator inlet tube retaining nut (1) and tighten to 16 N·m (12 lb ft).
  10. Install the evaporator inlet tube retaining screw.

    11. Object Number: 1190432 Size: SH
  11. Connect the blower motor resistor assembly electrical connector.

    12. Object Number: 1190441 Size: SH
  12. Connect the blower motor assembly electrical connector.

    13. Object Number: 924798 Size: SH
  13. Connect the low pressure sensor electrical connector (2).
  14. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
  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 .