GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Suzuki 🢒 2009 🢒 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. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the blower case assembly screws.

    6. 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 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.