GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 RELAY 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Evaporator Inlet Tube and Evaporator Outlet Tube Replacement

Evaporator Inlet Tube and Evaporator Outlet Tube Replacement w/C60

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

Important: Cap or tape the open air conditioning (A/C) components immediately in order to prevent system contamination.


    Object Number: 1547616 Size: SH
  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
  3. Remove the suction line to evaporator outlet tube bolt (1).
  4. Remove the suction line from the evaporator outlet tube.
  5. Cap or tape the suction line opening.
  6. Remove and discard the sealing washer (2).

    7. Object Number: 1547627 Size: SH
  7. Reposition the heater hoses in order to access the thermal expansion valve (TXV).
  8. Remove the evaporator inlet/outlet tube block nut at the TXV.
  9. Remove the evaporator inlet/outlet tube block from the TXV.
  10. Remove and discard the sealing washers.
  11. Cap or tape the TXV openings.

    12. Object Number: 1547622 Size: SH
  12. Remove the evaporator inlet tube to condenser bolt (2).
  13. Remove the evaporator inlet tube (5) from the condenser.
  14. Remove and discard the sealing washer.
  15. Cap or tape the condenser opening.
  16. Remove the electrical connector (3) from bracket.
  17. Remove the evaporator inlet/outlet tube bracket bolt (4).
  18. Remove the evaporator inlet/outlet tube clip to shock tower nut (6).
  19. Remove the evaporator inlet/outlet tube assembly.
  20. Remove the evaporator outlet tube (8) from the inlet tube (5).

Installation Procedure

    Object Number: 1547622 Size: SH
  1. Install the evaporator outlet tube (8) to the inlet tube (5).
  2. Install the evaporator inlet/outlet tube assembly.

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

  3. Install the evaporator inlet/outlet tube clip to shock tower nut (6).

    4. Tighten
    Tighten the nut to 5.5 N·m (49 lb in).

  4. Install a NEW sealing washer to the condenser end of the evaporator inlet tube.
  5. Remove the cap or tape from the condenser opening.
  6. Install the evaporator inlet tube (5) to the condenser.
  7. Install the evaporator inlet tube to condenser bolt (2).

    8. Tighten
    Tighten the bolt to 16 N·m (12 lb ft).

  8. Install the evaporator inlet/outlet tube bracket bolt (4).

    9. Tighten
    Tighten the bolt to 27 N·m (20 lb ft).

  9. Install the electrical connector (3) to bracket.

    10. Object Number: 1547627 Size: SH
  10. Install NEW sealing washers to the TXV end of the evaporator inlet/outlet tube.
  11. Remove the caps or tape from the TXV openings.
  12. Install the evaporator inlet/outlet tube block to the TXV.
  13. Install the evaporator inlet/outlet tube block nut at the TXV.

    14. Tighten
    Tighten the nut to 16 N·m (12 lb ft).


    Object Number: 1547616 Size: SH
  14. Install a NEW sealing washer (2) to the suction line.
  15. Remove the cap or tape from the suction line opening.
  16. Install the suction line to the evaporator outlet tube.
  17. Install the suction line to evaporator outlet tube bolt (1).

    18. Tighten
    Tighten the bolt to 16 N·m (12 lb ft).

  18. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

Evaporator Inlet Tube and Evaporator Outlet Tube Replacement W/C69

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

Important: Cap or tape the open air conditioning (A/C) components immediately in order to prevent system contamination.


    Object Number: 1547619 Size: SH
  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
  3. Remove the suction line to evaporator outlet tube bolt (1).
  4. Remove the suction line from the evaporator outlet tube.
  5. Cap or tape the suction line opening.
  6. Remove and discard the sealing washer (2).

    7. Object Number: 1547627 Size: SH
  7. Reposition the heater hoses in order to access the thermal expansion valve (TXV).
  8. Remove the evaporator inlet/outlet tube block nut at the TXV.
  9. Remove the evaporator inlet/outlet tube block from the TXV.
  10. Remove and discard the sealing washers.
  11. Cap or tape the TXV openings.

    12. Object Number: 1547626 Size: SH
  12. Remove the evaporator inlet tube to condenser bolt (2).
  13. Remove the evaporator inlet tube from the condenser.
  14. Remove and discard the sealing washer (5).
  15. Cap or tape the A/C condenser opening.

    16. Object Number: 1547623 Size: SH
  16. Remove the electrical connector from the bracket.
  17. Remove the evaporator inlet/outlet tube bracket bolt (3).
  18. Remove the evaporator inlet/outlet tube clip to shock tower nut (2).
  19. Remove the evaporator inlet/outlet tube nuts (4, 5) from the rear (auxiliary) evaporator inlet/outlet tubes.
  20. Remove and discard the sealing washers.
  21. Cap or tape the auxiliary evaporator inlet and outlet tubes.
  22. Remove the evaporator inlet/outlet tube assembly.
  23. Remove the evaporator outlet tube from the inlet tube, if necessary.

Installation Procedure

    Object Number: 1547623 Size: SH
  1. Install the evaporator outlet tube to the inlet tube, if necessary.
  2. Install NEW sealing washers to the front evaporator inlet/outlet to auxiliary evaporator inlet/outlet fittings.
  3. Install a NEW sealing washer to the condenser end of the evaporator inlet tube.
  4. Remove the cap or tape from the auxiliary evaporator inlet and outlet tubes.
  5. Remove the cap or tape from the condenser opening.
  6. Install the evaporator inlet tube to the condenser.
  7. Install the evaporator inlet/outlet tube assembly.

    8. Notice: Refer to Fastener Notice in the Preface section.

  8. Install the evaporator inlet/outlet tube nuts (4, 5) to the auxiliary evaporator inlet/outlet tubes.

    9. Tighten
    Tighten the nut to 16 N·m (12 lb ft).

  9. Install the evaporator inlet/outlet tube clip to shock tower nut (2).

    10. Tighten
    Tighten the nut to 5.5 N·m (49 lb in).

  10. Install the evaporator inlet/outlet tube bracket bolt (3).

    11. Tighten
    Tighten the bolt to 27 N·m (20 lb ft).

  11. Install the electrical connector to bracket.

    12. Object Number: 1547626 Size: SH
  12. Install the evaporator inlet tube to condenser bolt (2).

    13. Tighten
    Tighten the bolt to 16 N·m (12 lb ft).


    Object Number: 1547627 Size: SH
  13. Install NEW sealing washers to the TXV end of the evaporator inlet/outlet tube.
  14. Remove the caps or tape from the TXV openings.
  15. Install the evaporator inlet/outlet tube block to the TXV.
  16. Install the evaporator inlet/outlet tube block nut at the TXV.

    17. Tighten
    Tighten the nut to 16 N·m (12 lb ft).


    Object Number: 1547619 Size: SH
  17. Install a NEW sealing washer (2) to the suction line.
  18. Remove the cap or tape from the suction line opening.
  19. Install the suction line to the evaporator outlet tube.
  20. Install the suction line to evaporator outlet tube bolt (1).

    21. Tighten
    Tighten the bolt to 16 N·m (12 lb ft).

  21. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  22. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .