GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Suzuki 🢒 2007 🢒 XL-7 FWD 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Air Conditioning Evaporator Core Replacement

    Object Number: 1646787 Size: SH
  1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement .
  2. Remove the evaporator case assembly. Refer to Air Conditioning (A/C) Evaporator Case Assembly Replacement .
  3. Remove the thermal expansion valve (TXV) bolts from the backing plate.
  4. Remove the TXV and the backing plate from the evaporator pipes.
  5. Remove the seal washers from evaporator pipes. Refer to Sealing Washer Replacement .
  6. Remove the HVAC module front of dash seal.

    7. Object Number: 1646794 Size: SH
  7. Remove the screws retaining the two halves of the blower case assembly.
  8. Separate the two halves of the blower case assembly.

    9. Object Number: 1648495 Size: SH
  9. Remove the evaporator core from the blower case assembly.

Installation Procedure

    Object Number: 1648495 Size: SH
  1. Add the proper of polyalkylene glycol (PAG) oil to the evaporator core. Refer to Refrigerant System Capacities .
  2. Inspect the seal around the evaporator core. Make sure the seal is in correct position and retained properly.
  3. Install the evaporator core to the blower case assembly.

    4. Object Number: 1646794 Size: SH
  4. Assemble the two halves of the blower case assembly.

    5. 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.

  5. Install the blower case assembly screws.

    6. Tighten
    Tighten the screw to 1.5 N·m (13 lb in).

  6. Install the HVAC module front of dash seal.

    7. Object Number: 1646787 Size: SH
  7. Install new seal washers to the evaporator pipes. Refer to Sealing Washer Replacement .
  8. Instal the TXV and the backing plate to the evaporator pipes.
  9. Install the TXV screws to the backing plate.

    10. Tighten
    Tighten the screws to 3.5 N·m (31 lb in).

  10. Install the evaporator case assembly. Refer to Air Conditioning (A/C) Evaporator Case Assembly Replacement .
  11. Install the HVAC module. Refer to HVAC Module Assembly Replacement .