GM Service Manual Online
For 1990-2009 cars only

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. Refer to the appropriate procedure:
  3. •  Air Cleaner Replacement in Engine Controls - 7.2L (Caterpillar)
    •  Air Cleaner Replacement in Engine Controls - 8.1L
    •  Air Cleaner Replacement in Engine Controls - 7.8L
    • Caterpillar® 3126 Unit Repair Manual
  4. Remove the right wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.

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

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

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

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 800353  Size: SH
  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).

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

  4. Object Number: 800358  Size: SH
  5. Install the evaporator inlet tube to the evaporator.
  6. Install the evaporator tube retaining nut (3).
  7. Tighten
    Tighten the nut to 16 N·m (12 lb ft).


    Object Number: 770250  Size: SH
  8. Install the retaining bolt to the evaporator inlet tube bracket (3).
  9. Tighten
    Tighten the bolt to 9 N·m (60 lb in).

  10. Install the air cleaner. Refer to the appropriate procedure:
  11. •  Air Cleaner Replacement in Engine Controls - 7.2L (Caterpillar)
    •  Air Cleaner Replacement in Engine Controls - 8.1L
    •  Air Cleaner Replacement in Engine Controls - 7.8L
    • Caterpillar® 3126 Unit Repair Manual
  12. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  14. Leak test the fittings of the components using the J 39400-A .