GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Tahoe - 4WD 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Evaporator Tube Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging
  3. Disconnect the auxiliary heater hose, if equipped. Refer to Heater Hoses Replacement - Auxiliary .
  4. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement

    5. Object Number: 257983 Size: SH
  5. Disconnect the evaporator tube from the evaporator.
  6. Remove the O-ring seal.
  7. Disconnect the evaporator tube from the condenser.
  8. Remove the O-ring seal.
  9. Remove the tube from the clip.

Installation Procedure

    Object Number: 257983 Size: SH
  1. Install the evaporator tube into the clip.
  2. Coat the new O-ring seal with 525 viscosity refrigerant oil.
  3. Install the new O-ring seal.

    4. 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.

  4. Connect the evaporator tube to the condenser.

    5. Tighten
    Tighten the evaporator tube to 24 N·m (18 lb ft).

  5. Coat the new O-ring seal with 525 viscosity refrigerant oil.
  6. Install the new O-ring seal.
  7. Install the evaporator tube to the evaporator.

    8. Tighten
    Tighten the evaporator tube to 24 N·m (18 lb ft).

  8. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement
  9. Connect the auxiliary heater hose, if equipped. Refer to Heater Hoses Replacement - Auxiliary .
  10. Connect the negative battery cable.
  11. Charge the system. Refer to Refrigerant Recovery and Recharging
  12. Inspect the system for leaks. Refer to Leak Testing .