Tools Required

J 39400-A Halogen Leak Detector

Important: Install the A/C refrigerant filter, AC Delco P/N 15-1697, to the A/C evaporator tube between the condenser and evaporator. The installation of this filter eliminates the need for flushing.

1. Remove the PCM. Refer to Powertrain Control Module Replacement in Engine Controls-4.3L.
2. Remove the engine coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
3. Loosen the accumulator nut at the evaporator.



4. Reposition the accumulator (4) in order to gain access to the evaporator tube (1).
5. Measure 100 mm (4 in) from the bend after the high side access port and mark the location.
6. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step.

Important: Do not allow metal burrs to enter the tube during cutting or when removing the burrs.

7. Using a tubing cutter, cut the marked section of the evaporator tube (1).
8. Remove the burrs from the evaporator tube (1).



9. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1).

Important: DO NOT install the O-rings (2) in this step.

10. Push the nuts (4), and the ferrules (3) over each of the evaporator tube halves.
11. Install the ferrules (3) with the small end toward the nut (4).
12. Install the A/C refrigerant filter (1) to the evaporator tube with the flow arrow pointing towards the evaporator.

Notice: Refer to Fastener Notice in the Preface section.

13. Install the nuts (4) to the A/C refrigerant filter (1).

Tighten
Tighten the nuts to 15 N·m (11 lb ft).

14. Remove the nuts (4) from the A/C refrigerant filter (1).
15. Coat the O-ring seals with 525 viscosity refrigerant oil.
16. Install the O-rings (2) to the evaporator tube.
17. Install the nuts (4) to the A/C refrigerant filter (1).

Tighten
Tighten the nuts to 15 N·m (11 lb ft).




18. Install accumulator (4) to the evaporator (3).
19. Tighten the accumulator nut at the evaporator.

Tighten
Tighten the nut to 15 N·m (11 lb ft).

20. Position the accumulator bracket 60 mm (2.36 in) toward the high side access port.
21. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
22. Leak test the fittings of the component using the J 39400-A .
23. Install the engine coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
24. Install the PCM. Refer to Powertrain Control Module Replacement in Engine Controls-4.3L.