SERVICE MANUAL UPDATE-SEC. 1B A/C EVAPORATOR (FRONT)

SUBJECT: SECTION IB, A/C EVAPORATOR (FRONT)

VEHICLES AFFECTED: 1990-93 "U" CHEVROLET LUMINA APV AND APV CARGO

This bulletin replaced GMCL Bulletin 93-10-603 in its entirety. A Separate bulletin for Oldsmobile and Pontiac will be issued in the near future.

APPLICATION: 1990-93 CHEVROLET LUMINA APV AND APV CARGO

This bulletin serves to cancel and supersede the A/C evaporator procedures found in Section 1B of the 1990-93 Chevrolet Lumina APV Service Manuals. Use this procedure whenever service of the A/C Evaporator is necessary.

A/C Evaporator (Front) Figures 1 through 21

REMOVE OR DISCONNECT

Recover refrigerant. Refer to SECTION 1B. Drain engine coolant. Refer to SECTION 6B

1. Two screws (838) attaching RH windshield wiper transmission (837) arm to windshield wiper frame (836) (Figure 1). Move RH windshield wiper transmission arm aside to gain access to heater hoses. 2. Clamp and heater outlet hose (105) from heater core (123) (Figure 2). 3. Clamp and heater inlet hose (104) from heater core (123) (Figure 2). 4. RH I/P sound insulator panel push-in retainers (803), screw (806) and nut (805) from stud (Figure 3). Carefully pull RH I/P sound insulator panel (802) away from I/P (Figure 3) 5. Floor (courtesy) lamp (804) from RH I/P sound insulator panel (802) (Figure 3). 6. RH I/P sound insulator panel (802) from vehicle (Figure 3). Open I/P compartment door. 7. Three screws (809) from bottom of I/P compartment insert (808) (Figure 4). 8. Three upper I/P compartment screws (809) with two bumpers (810) (Figure 4). 9. Electrical connector from I/P compartment lamp and switch assembly.

10. I/P compartment (with door) (808) from I/P (Figure 4). 11. Bolt (i13) and nut (115) from I/P lower brace (114) (early model vehicles) (Figure 5). 12. I/P lower brace (114) from I/P (early model vehicles) (Figure 5). 13. Two screws (839) retaining I/P lower extension housing (801) to I/P lower extension support brackets (840) (1993 vehicles only) (Figure 6). 14. RH I/P outer support-to-I/P lower trim pad attaching bolt (812) (Figure 7). Position wedge between RH I/P outer support (81 1) and I/P lower trim pad (807) (Figure 7). Wedge will provide sufficient clearance for removal and installation of heater core. 15. Heater and A/C control vacuum harness (117) from vacuum/electric solenoid (116) (Figure 8). 16. Two screws retaining vacuum/electric solenoid (116) (Figure 8). 17. Vacuum/electric solenoid (116) from heater core cover (112) (Figure 8). 18. Six screws (147) and two clips (122) from heater core cover (112) (Figure 9). 19. Heater core cover (112) and seal (118) from temperature case (126) (Figure 9). 20. Heater core lower bracket retaining screw (late model vehicles). 21. Heater core lower bracket (late model vehicles). 22. LH retaining screw from heater core upper bracket (late model vehicles).

Loosen RH retaining screw from heater core upper bracket (late model vehicles). Adjust heater core upper bracket to allow heater core removal (late model vehicles)

23. Heater core inlet/outlet tubes from tube/case seal (120) (Figure 9). 24. Heater core (123) and seal (119) from temperature case (126) (Figure 9). 25. Rear window wiper and washer switch (816) from instrument cluster housing (815) (Figure 10). Disconnect electrical connector from switch. 26. Headlamp switch (817) from instrument cluster housing (815) (Figure 10). Disconnect electrical connector from switch. 27. Four screws (813) retaining instrument cluster housing (815) to I/P trim pad (818) (Figure 10). 28. Instrument cluster housing (815) from I/P trim pad (818) (Figure 10). 29. Two screws (821) retaining LH I/P sound insulator panel (819) to I/P steering column opening filler (823) (Figure 11). 30. One screw (821) retaining LH I/P sound insulator panel (819) to I/P lower extension housing (801) (Figure 11). 31. Two nuts (822) retaining LH I/P sound insulator panel (819) to studs (Figure 11). 32. Floor (courtesy) lamp (820) from LH I/P sound insulator panel (819) while carefully pulling panel away from I/P (Figure 11). 33. RH screw (821) attaching I/P steering column opening filler (823) to I/P lower trim pad (807) (Figure 12). 34. I/P steering column opening filler (823) from slots in I/P lower trim pad (807) by pulling rearward and downward to release four clips (824) (Figure 12). 35. Shift indicator cable (303) from transaxle control lever bowl (304) (Figure 13). 36. Screws (826) retaining instrument cluster (825) to I/P trim pad (818) (Figure 14). 37. Instrument cluster (825) from I/P trim pad (818) to gain access to shift indicator cable (Figure 14). 38. Shift indicator cable (303) from cable bracket and instrument cluster (825) from I/P trim pad (818). 39. LH and RH side window defogger outlet grilles (829) from I/P trim pad (818) (Figure 15). 40. Screws (830) behind side window defogger outlet grilles (829) (one on each side of I/P trim pad) (Figure 15). 41. Two screws (831) (one on each side of instrument cluster area) retaining I/P trim pad (818) to I/P lower trim pad (807) (Figure 15). 42. Two screws (832) (above I/P compartment area) retaining I/P trim pad (81 8) to I/P lower trim pad (807) (Figure 16). 43. Switch harness clips from I/P trim pad. 44. Instrument cluster electrical connector from I/P trim pad (818). 45. DRL sensor (833) from I/P trim pad (818) (if equipped) (Figure 17). 46. I/P trim pad (818) from seated position. Feed harnesses through I/P trim pad (818) and remove pad from vehicle. 47. Electrical connector and harness from temperature valve actuator (109) (Figure 18). 48. Two screws from temperature valve actuator (109) and actuator from temperature case (126) (Figure 18). 49. Two lower screws (130) from temperature case (Figure 19). 50. One upper LH screw (130), one upper RH screw (i30), temperature case (126) and gasket (129) from blower and air inlet case (128) (Figure 19). Removal of upper RH temperature case screw (130) may require partial removal of adhesive insulator patch. 51. A/C accumulator hose (133) from A/C evaporator (144) (Figure 20). 52. A/C evaporator hose (136) from A/C evaporator (144) (Figure 20). 53. Four screws (132) retaining auxiliary A/C evaporator and blower case (i31) to blower and air inlet case (128) (Figure 20). 54. Windshield defogger nozzle duct (127) (Figure 18). 55. A/C evaporator (144) inlet/outlet tubes from drain grommet and A/C evaporator (with case) from blower and air inlet case (128) (Figure 21). 56. Tube and drain seal (140) from A/C evaporator (144) (Figure 21). 57. One screw (137) retaining evaporator tube clamp (138) (Figure 21). 58. Four A/C evaporator case clips (143) (Figure 21).

Separate upper and lower auxiliary A/C evaporator and blower case halves (131) (Figure 21).

59. Six stake retainers (142) and filter (141) from A/C evaporator (144) (Figure 21). 60. Evaporator core mounting spacers (139) (Figure 21). 61. Evaporator core seal (145) (Figure 21).

INSPECT

1. A/C evaporator (144) for signs of damage, leakage or internal restriction. Replace as necessary. 2. Evaporator core seal (145) for damage or deformation. Replace as necessary. 3. Tube and drain seal (140) for damage or deformation. Replace as necessary. 4. Drain grommet for damage or deformation. Replace as necessary.

INSTALL OR CONNECT

1. Evaporator core seal (145) (Figure 21). 2. New evaporator core mounting spacers (1 39) (Figure 21). 3. New filter (141) to A/C evaporator (144) with six stake retainers (142) (Figure 21). 4. A/C evaporator (144) into upper and lower auxiliary A/C evaporator and blower case halves (131) (Figure 21). 5. Upper and lower auxiliary A/C evaporator and blower case halves (131) with four A/C evaporator case clips (143) (Figure 21). 6. Evaporator tube clamp (138) with screw (137) (Figure 21).

Tighten Evaporator tube clamp screw (1 37) to 7 N.m (62 lb.in.).

7. Tube and drain seal (140) to A/C evaporator (144) (Figure 21). 8. A/C evaporator inlet/outlet tubes to drain grommet and A/C evaporator (with case) (144/131) into blower and air inlet case (128) (Figure 19). 9. Windshield defogger nozzle duct (127) (Figure 18). 10. Four screws (132) retaining auxiliary A/C evaporator and blower case (131) to blower and air inlet case (128) (Figure 20).

Tighten Auxiliary A/C evaporator and blower case screws (132) to 10 N.m (89 lb.in.).

Important: Lubricate new 0-ring seals prior to installation with 525 viscosity mineral refrigerant oil only. Do not use PAG oil to lubricate 0-ring seals.

11. A/C evaporator hose (136) to A/C evaporator (144) with new 0-ring seal (135) (Figure 20). 12. A/C accumulator hose (133) to A/C evaporator (144) with new 0-ring seal (134) (Figure 20). 13. Temperature case (126) and new gasket (129) to blower and air inlet case with two upper screws (130) (Figure 19).

Tighten Upper temperature case-to-blower and air inlet case screws (130) to 7 N.m (62 lb.in.).

14. Two lower screws (130) to temperature case (Figure 19).

Tighten Lower temperature case-to-blower and air inlet case screws (130) to 7 N.m (62 lb.in.).

15. Temperature valve actuator (109) to temperature case (126) with two screws (Figure 18).

Tighten Temperature valve actuator screws to 8 N.m (71 lb.in.).

16. Electrical connector and harness to temperature valve actuator (l09) (Figure 1 8). 17. DRL sensor (833) to I/P trim pad (818) (if equipped) (Figure 17). 18. Electrical harnesses through I/P trim pad (818) and position pad onto I/P lower trim pad (807). 19. Instrument cluster connector to I/P trim pad (818). 20. Electrical harnesses to I/P trim pad (818) with clips. 21. Two screws (832) (above I/P compartment area) attaching I/P trim pad (818) to I/P lower trim pad (807) (Figure 16).

Tighten I/P trim pad-to-I/P lower trim pad attaching screws (832) to 2 N.m (18 lb.in.).

22. Two screws (831) (one on each side of instrument cluster area) attaching I/P trim pad (818) to I/P lower trim pad (807) (Figure 15).

Tighten I/P trim pad-to-I/P lower trim pad attaching screws (831) to 3 N.m (27 lb. in.)

23. Screws (830) behind side window defogger outlet grilles (829) (one on each side of I/P trim pad) (Figure 15).

Tighten I/P trim pad-to-I/P lower trim pad attaching screws (830) to 3 N.m (27 lb.in.).

24. LH and RH side window defogger outlet grilles (829) to I/P trim pad (818) (Figure 15). 25. Shift indicator cable (303) to cable bracket and instrument cluster (825) to I/P trim pad (818). 26. Instrument cluster (825) to I/P trim pad (818) with attaching screws (826) (Figure 14).

Tighten Instrument cluster-to-I/P trim pad attaching screws (826) to 3 N.m (27 lb.in.).

27. Shift indicator cable (303) to transaxle control lever bowl (304) (Figure 13).

ADJUST

0 Position automatic transaxle control lever in "N" (Neutral) gate notch. 0 Guide shift indicator cable (303) around edge of transaxle control lever bowl into a position that locates the instrument cluster pointer on the "N" (Neutral). 0 Push shift indicator cable (303) onto transaxle control lever bowl (304). Care must be taken to assure that shift indicator cable (304) rests on transaxle control lever bowl and not steering column jacket (302) (Figure 13). 0 Check that, with automatic transaxle control lever in "N" (Neutral) position, the "N" is visible on both sides of the instrument cluster pointer. 0 Check that, with automatic transaxle control lever in "1" (Low) position, the pointer must cover portions of the "1" or be to the right of the "1".

28. I/P steering column opening filler (823) by inserting four clips (824) into slots in I/P lower trim pad (807) (Figure 12).

29. RH I/P steering column opening filler attaching screw (821) (Figure 12).

Tighten I/P steering column opening filler attaching screw (821) to 3 N.m (27 lb.in.).

30. Floor (courtesy) lamp (820) to LH I/P sound insulator panel (819) while carefully positioning panel into I/P. 31. Two nuts (822) retaining LH I/P sound insulator panel (819) to studs (Figure 11). 32. One screw (821) retaining LH I/P sound insulator panel (819) to I/P lower extension housing (801) (Figure 11). 33. Two screws (821) retaining LH I/P sound insulator panel (819) to I/P steering column opening filler (823) (Figure 11).

Tighten LH I/P sound insulator attaching screws (821) to 3 N.m (27 lb.in.).

34. Instrument cluster housing (815) to I/P trim pad (818) with four retaining screws (813) (Figure 10).

Tighten Instrument cluster housing retaining screws (813) to 2 N.m (l8 lb.in.).

35. Electrical connector to headlamp switch (817) (Figure 10). 36. Headlamp switch (817) to instrument cluster housing (815) (Figure 10). 37. Electrical connector to rear window wiper and washer switch (816) (Figure 10). 38. Rear window wiper and washer switch (816) to instrument cluster housing (815) (Figure 1 0). 39. Heater core inlet/outlet tubes into tube/case seal (120) and heater core (123) and seal (119) into temperature case (126) (adjusting heater core upper bracket if equipped) (Figure 9). 40. LH retaining screw to heater core upper bracket - do not fully tighten (late model vehicles). 41. Heater core lower bracket with retaining screw (late model vehicles).

Adjust positioning of heater core in temperature case to prevent any movement.

Tighten Heater core bracket retaining screws to 3 N.m (27 lb.in.).

42. Heater core cover (112) and seal (118) to temperature case (126) with six screws (147) and two clips (122) (Figure 9).

Tighten Heater core cover screws (147) to 7 N.m (62 lb.in.).

43. Vacuum/electric solenoid (116) to heater core cover (112) with two screws (Figure 8).

Tighten Vacuum/electric solenoid screws to 7 N.m (62 lb.in.).

44. Heater and A/C control vacuum harness (117) to vacuum/electric solenoid (116) (Figure 8). Remove wedge from between RH I/P outer support (811) and I/P lower trim pad (807) (Figure 7). 45. RH I/P outer support-to-I/P lower trim pad attaching bolt (812) (Figure 7).

Tighten RH I/P outer support-to-I/P lower trim pad attaching bolt (812) to 10 N.m (89 lb.in.).

46. Two screws (839) retaining I/P lower extension housing (801) to I/P lower extension support brackets (840) (Figure 6).

Tighten I/P lower extension housing-to-I/P lower extension support bracket screws to 3 N.m (27 lb.in.).

47. I/P lower brace (114) with nut (115) and bolt (113) (early model vehicles) (Figure 5).

Tighten 0 I/P lower brace nut (1 15) to 1 0 N. m (89 lb.in.). 0 I/P lower brace bolt (1 13) to 8 N.m (71 lb.in.).

48. Electrical connector to I/P compartment lamp and switch assembly while positioning I/P compartment into I/P (with door open). 49. Three upper I/P compartment screws (809) with two bumpers (810) (Figure 4). 50. Three lower I/P compartment screws (809) (Figure 4).

Tighten 0 I/P compartment screws (809) to 3 N.m (27 lb.in.). 0 Close I/P compartment door.

51. Floor (courtesy) lamp (804) to RH I/P sound insulator panel (802) while positioning panel into I/P (Figure 3). 52. RH I/P sound insulator panel screw (806), nut (805) and push-in retainers (803) (Figure 3).

Tighten

0 RH I/P sound insulator panel attaching screw (806) to 3 N.m (27 lb. in.).

53. Heater inlet hose (104) to heater core (123) and secure with clamp (Figure 2).

54. Heater outlet hose (105) to heater core (123) and secure with clamp (Figure 2).

55. Two screws (838) attaching RH windshield wiper transmission (837) arm to windshield wiper frame (836) (Figure 1).

Tighten

RH windshield wiper transmission arm-to-windshield wiper frame screws (838) to 7 N.m (62 lb.in.). Refill engine coolant. Refer to SECTION 6B. Recharge refrigerant.

For vehicles repaired under warranty use:

Labour Operation: D3320 Labour Time: 2.7 Hrs

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.