GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Conventional) C6/C7/C8 🢒 Engine 🢒 Engine Electrical 🢒 Air Conditioning Evaporator Tube Replacement - Inlet

Tools Required

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 air cleaner layer. Refer to the appropriate procedure:
    3. •  Air Cleaner Replacement in Engine Controls-6.6L.
    •  Air Cleaner Replacement in Engine Controls-8.1L.
    •  Air Cleaner Replacement in Engine Controls-7.8L.
    • Caterpillar® 3126 Unit Repair Manual
  3. Remove the right wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.

    4. Object Number: 770250 Size: SH
  4. Remove the retaining bolt (2) from the evaporator inlet tube bracket (3).

    5. Object Number: 800358 Size: SH
  5. Remove the retaining nut (3) from evaporator inlet tube (5).
  6. Remove the sealing washer.

    7. Object Number: 800353 Size: SH
  7. Disconnect the evaporator tube fitting (3) from the evaporator hose fitting (2).

Installation Procedure

    Object Number: 800353 Size: SH

    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.

  1. Connect the evaporator tube fitting (3) to the evaporator hose fitting (2).

    2. Tighten
    Tighten the fittings to 35 N·m (18 lb ft).

  2. Install the new seal washer. Refer to Sealing Washer Replacement .

    3. Object Number: 800358 Size: SH
  3. Install the evaporator inlet tube to the evaporator.
  4. Install the evaporator tube retaining nut (3).

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


    Object Number: 770250 Size: SH
  5. Install the retaining bolt to the evaporator inlet tube bracket (3).

    6. Tighten
    Tighten the bolt to 9 N·m (60 lb in).

  6. Install the air cleaner layer. Refer to the appropriate procedure:
    7. •  Air Cleaner Replacement in Engine Controls-6.6L.
    •  Air Cleaner Replacement in Engine Controls-8.1L.
    •  Air Cleaner Replacement in Engine Controls-7.8L.
    • Caterpillar® 3126 Unit Repair Manual
  7. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  9. Leak test the fittings of the components using the J 39400-A .