GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Express 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Auxiliary Air Conditioning Evaporator Tube Replacement

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
  2. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.

    3. Object Number: 556745 Size: SH
  3. Remove the auxiliary evaporator hose (1) from the condenser hose (3).
  4. Remove the retaining nut from the engine.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    6. Object Number: 556747 Size: SH
  6. Remove the auxiliary evaporator tube (1) retaining nuts (2) from the body.
  7. Remove the bolt retaining the hose to the transmission bracket.
  8. Remove the evaporator tube from the rear evaporator hose.
  9. Remove the evaporator tube from the vehicle.

Installation Procedure

    Object Number: 556747 Size: SH

    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.

  1. Connect the evaporator tube (1) to the vehicle.

    2. Tighten
    Tighten the hose fitting to 48 N·m (35 lb ft).

  2. Install the evaporator tube retaining nuts (2) to the engine and the body.

    3. Tighten
    Tighten the retaining nuts to 6 N·m (53 lb in).


    Object Number: 556745 Size: SH
  3. Install the bolt retaining the hose (1) to the transmission bracket.

    4. Tighten
    Tighten the retaining bolt to 5 N·m (44 lb in).

  4. Lower the vehicle.
  5. Install the auxiliary evaporator hose connection to the A/C compressor.

    6. Tighten
    Tighten the fitting to 48 N·m (35 lb ft).

  6. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  8. Leak test the fittings of the components using the J 39400-A .