GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Air Conditioning Evaporator Hose Assembly Replacement

Removal Procedure
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.

    2. Object Number: 1936934 Size: SH
  2. Disconnect the evaporator hose (2) at the condenser.

    3. Object Number: 1938645 Size: LH
  3. Remove the right side engine damping block (1). Refer to Engine Mount Replacement - Right Side.

    4. Object Number: 1936941 Size: SH
  4. Disconnect the compressor hose (1) from the evaporator hose.
  5. Disconnect the evaporator hose at the thermal expansion valve (TXV).

Installation Procedure
  1. Install the evaporator hose to the vehicle.
  2. Install new seals to the evaporator hose at the TXV.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the evaporator hose to the TXV.

    4. Tighten
    Tighten the block connector bolt to 7 N·m (62 lb in).


    Object Number: 1936941 Size: SH
  4. Install a new seal at the compressor hose joint.
  5. Connect the evaporator hose to the compressor hose (1).

    6. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 1936934 Size: SH
  6. Install a new seal to the evaporator hose.
  7. Install the evaporator hose (2) to the condenser.

    8. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 1938645 Size: LH
  8. Install the right side engine damping block (1). Refer to Engine Mount Replacement - Right Side.
  9. Recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging.