Auxiliary Air Conditioning Evaporator Replacement Tahoe/Yukon

Tools Required

J 39400-A Halogen Leak Detector

1. Remove the auxiliary HVAC module (4) from the vehicle. Refer to Auxiliary HVAC Module Replacement .



2. Remove the air temperature actuator (1) from the auxiliary HVAC module.



3. Remove the heater core cover (1) from the auxiliary HVAC module.



4. Remove the heater core (1) from the auxiliary HVAC module.



5. Remove the lower module cover from the auxiliary HVAC module.



6. Remove the evaporator core from the lower module cover.

1. Install the evaporator core to the lower module cover.



2. Install the lower module cover to the auxiliary HVAC module.



3. Install the heater core (1) to the auxiliary HVAC module.



4. Install the heater core cover (1) to the auxiliary HVAC module.



5. Install the air temperature actuator (1) to the auxiliary HVAC module.



6. Install the auxiliary HVAC module assembly  (4) to the vehicle. Refer to Auxiliary HVAC Module Replacement .

Auxiliary Air Conditioning Evaporator Replacement Suburban/Yukon XL

Tools Required

J 39400-A Halogen Leak Detector

1. Remove the auxiliary HVAC module (3) from the vehicle. Refer to Auxiliary HVAC Module Replacement .



2. Remove the air temperature actuator (1).
3. Remove the stud on the underside of the rear HVAC module between the heater core inlet and outlet pipes (4).
4. Carefully separate the heater core pipe gasket from the module case and remove the heater core pipe retainer.



5. Remove the screws from the HVAC module lower cover.
6. Remove the auxiliary HVAC module lower cover.



7. Remove the heater core clamp.
8. Remove the heater core from the auxiliary HVAC module.
9. Carefully remove the gasket between the auxiliary HVAC module and the air distributor duct. This gasket will be re-used if possible.



10. Remove the fasteners and separate the front case half from the back half.
11. Remove the evaporator core from the back case half.
12. Inspect the gaskets and the seals for damage.
13. Replace the gaskets and the seals, as needed.

1. Install the evaporator core into the case.
2. Install the evaporator core seal.

Important: Ensure the proper positioning of the air distributor duct gasket and the temperature door during assembly.

3. Reassemble the case halves.



4. Install the heater core to the auxiliary HVAC module.
5. Install the heater core clamp.



6. Install the auxiliary HVAC module lower cover.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the screws to the HVAC module lower cover.

Tighten
Tighten the screws to 1.6 N·m (14 lb in).

8. Install the heater core pipe retainer and gasket.
9. Install the stud between the heater core inlet and outlet on the underside of the auxiliary HVAC module.



10. Install the air temperature actuator (1).



11. Install the auxiliary HVAC module (3) to the vehicle. Refer to Auxiliary HVAC Module Replacement .