Skip to content
Tahoe / Yukon Service Manual

Heater and Air Conditioning Evaporator and Blower Module Removal and Installation

Heater and Air Conditioning Evaporator and Blower Module Removal and Installation Single Use Fasteners and Components Air Conditioning Evaporator Thermal Expansion Valve Seal - Large [2x] Air Conditioning Evaporator Thermal Expansion Valve Seal - Small [2x] Special Tool Wipers and Washers J-39822 Wiper Arm Puller Equivalent regional tools: Special Tools Removal Procedure

  1. Disconnect the negative battery cable. Battery Negative Cable Disconnection and Connection
  2. Recover the refrigerant. Refrigerant Recovery and Recharging
  3. Drain the coolant. Cooling System Draining and Filling
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 1
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 1
  1. Starting at the rear of the right front side door sill garnish molding (1) pull upward at the B- pillar joint to disengage the garnish molding.
  2. Work your way forward disengaging all the right front side door sill garnish molding retaining clips and then pull rearward to disengage the 2 retaining clips on the forward vertical wall.
  3. Front Side Door Sill Garnish Molding - Right Side (1) » Remove
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 2
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 2
  1. Instrument Panel Lower Insulator Retainer (1) » Remove [3x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 3
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 3
  1. Instrument Panel Lower Trim Panel Insulator (1) » Remove
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 4
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 4
  1. {with C3A} Ground Nut (2) » Remove 9.1. Disconnect the electrical connector. (3) 9.2. Ground terminal (4) » Remove
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 5
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 5
  1. Instrument Panel Carrier (1) » Remove — Instrument Panel Carrier Replacement
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 6
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 6
  1. Data Link Connector Bolt (1) » Remove [2x]
  2. Data Link Connector (2) » Reposition away
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 7
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 7
  1. Instrument Panel Driver Knee Bolster Brace Bolt (1) » Remove [4x]
  2. Instrument Panel Knee Bolster Deflector (2) » Remove
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 8
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 8
  1. Heater and Air Conditioning Evaporator and Blower Module Bolt (1) » Remove
  2. Use a suitable tool to push the tab (2) down.
  3. Instrument Panel Tie Bar Bolt (3) » Remove
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 9
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 9
  1. Instrument Panel Tie Bar Bolt (1) » Remove
  2. Use a suitable tool to push the tab (2) down.
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 10
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 10
  1. Instrument Panel Tie Bar Bolt (1) @ Floor Panel Tunnel Panel » Remove [2x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 11
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 11
  1. Body Hinge Pillar Outer Panel Hole Plug (1) » Remove [2x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 12
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 12
  1. Instrument Panel Tie Bar Bolt (1) @ Front Side Door » Remove [2x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 13
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 13
  1. Body Hinge Pillar Outer Panel Hole Plug (1) » Remove [2x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 14
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 14
  1. Instrument Panel Tie Bar Bolt (1) @ Front Side Door » Remove [2x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 15
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 15
  1. Using the appropriate trim tool, remove the 2 windshield wiper arm finish caps (1) from both windshield wiper arms (3).
  2. Windshield Wiper Arm Nut (2) » Remove [2x]
  3. Use the J-39822 Wiper Arm Puller to remove the windshield wiper arms (3) from the left and right side windshield wiper transmission pivot shaft.
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 16
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 16
  1. Apply two layers of masking tape to the painted surface around the top edge of the air inlet grille panel extensions (1) to prevent paint damage.
  1. Using a suitable plastic trim tool, carefully release the air inlet grille panel extension clips.
  2. Air Inlet Grille Panel Extension (1) » Remove [2x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 17
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 17
  1. Hood Rear Outer Air Inlet Seal Retainer (1) » Remove [2x]
  2. Hood Rear Outer Air Inlet Seal (2) » Remove [2x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 18
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 18
  1. Air Inlet Grille Panel Retainer (1) » Remove [8x]
  2. Windshield Washer Nozzle Hose » Disconnect [3x]
  3. Lift the front edge of the air inlet grille panel (2) and slide the panel forward from both hood hinges to remove.
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 19
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 19
  1. Windshield Wiper System Module Shield (1) » Remove
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 20
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 20
  1. Instrument Panel Tie Bar Bolt (1) @ Plenum Lower Panel » Remove [2x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 21
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 21
  1. Heater and Air Conditioning Evaporator and Blower Module Bolt (1) @ Heater and Air Conditioning Evaporator and Blower Module » Remove [5x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 22
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 22
  1. Disconnect the wiring harness from the instrument panel tie bar assembly (1) as necessary.
  2. Instrument Panel Tie Bar (1) » Remove
  3. Support the heater and air conditioning evaporator and blower module.
  4. With the aid of an assistant, remove the instrument panel tie bar assembly from the vehicle. (1)
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 23
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 23
  1. Air Conditioning Condenser and Evaporator Hose Clip (1) @ Battery Tray » Remove
  2. Air Conditioning Compressor and Condenser Hose Nut (2) » Remove
  3. Air Conditioning Compressor and Condenser Hose (3) » Remove
  4. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (4) » Remove and DISCARD
  5. Air Conditioning Condenser and Evaporator Hose (5) » Remove
  6. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (6) » Remove and DISCARD
  7. Air Conditioning Refrigerant Heat Exchanger Nut (7) » Remove
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 24
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 24
  1. Heater Outlet Hose Retainer (2) » Disengage
  2. Heater Outlet Hose (1) » Remove
  3. Heater Outlet Hose Retainer (4) » Disengage
  4. Heater Inlet Hose (3) » Remove
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 25
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 25
  1. Retainer (1) » Disengage [2x]
  2. Auxiliary Heater Inlet and Outlet Hose (2) @ Heater Core » Remove [2x]
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 26
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 26
  1. Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) » Remove
  2. Air Conditioning Refrigerant Heat Exchanger (2) » Remove
  3. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) » Remove and DISCARD
  4. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) » Remove and DISCARD
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 27
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 27
  1. Heater and Air Conditioning Evaporator and Blower Module Bolt (1) @ Dash Panel » Remove
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 28
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 28

  1. Heater and Air Conditioning Evaporator and Blower Module (1) » Remove

  2. With aid of an assistant remove the heater and air conditioning evaporator and blower module  (1) from the vehicle. Installation Procedure

  3. With aid of an assistant install the heater and air conditioning evaporator and blower module (1) onto the vehicle.

  4. Heater and Air Conditioning Evaporator and Blower Module (1) » Install

  5. Support the heater and air conditioning evaporator and blower module.

  1. Heater and Air Conditioning Evaporator and Blower Module Bolt (1) @ Dash Panel » Install and tighten — Fastener Specifications

  2. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) » Install NEW

  3. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) » Install NEW

  4. Air Conditioning Refrigerant Heat Exchanger (2) » Install

  5. Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) » Install and tighten — Fastener Specifications

  6. Auxiliary Heater Inlet and Outlet Hose (2) @ Heater Core » Install [2x]

  7. Retainer (1) » Engage [2x]

  8. Heater Inlet Hose (3) » Install

  9. Heater Outlet Hose Retainer (4) » Engage

  10. Heater Outlet Hose (1) » Install

  11. Heater Outlet Hose Retainer (2) » Engage

  12. Air Conditioning Refrigerant Heat Exchanger Nut (7) » Install and tighten — Fastener Specifications

  13. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (6) » Install NEW

  14. Air Conditioning Condenser and Evaporator Hose (5) » Install

  15. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (4) » Install NEW

  16. Air Conditioning Compressor and Condenser Hose (3) » Install

  17. Air Conditioning Compressor and Condenser Hose Nut (2) » Install and tighten — Fastener Specifications

  18. Air Conditioning Condenser and Evaporator Hose Clip (1) @ Battery Tray » Install

  19. With the aid of an assistant, position the instrument panel tie bar assembly into the vehicle.

  20. Instrument Panel Tie Bar (1) » Install

  21. Attach the wiring harness and connect the electrical connectors as necessary.

  22. Remove the support supporting the heater and air conditioning evaporator and blower module.

  1. Heater and Air Conditioning Evaporator and Blower Module Bolt (1) @ Heater and Air Conditioning Evaporator and Blower Module » Install and tighten [5x] — Fastener Specifications

  2. Instrument Panel Tie Bar Bolt (1) @ Plenum Lower Panel » Install and tighten [2x] — Fastener Specifications

  1. Instrument Panel Tie Bar Bolt (1) @ Front Side Door » Install and tighten [2x] — Fastener Specifications
  1. Body Hinge Pillar Outer Panel Hole Plug (1) » Install [2x]
  1. Instrument Panel Tie Bar Bolt (1) @ Front Side Door » Install and tighten [2x] — Fastener Specifications

  1. Body Hinge Pillar Outer Panel Hole Plug (1) » Install [2x]

  2. Instrument Panel Tie Bar Bolt (1) @ Floor Panel Tunnel Panel » Install and tighten [2x] — Fastener Specifications

  3. Instrument Panel Tie Bar Bolt (1) » Install and tighten — Fastener Specifications

  4. Use a suitable tool to push the tab (2) in the up position.

  5. Heater and Air Conditioning Evaporator and Blower Module Bolt (1) » Install and tighten — Fastener Specifications

  6. Use a suitable tool to push the tab (2) in the up position.

  7. Instrument Panel Tie Bar Bolt (3) » Install and tighten — Fastener Specifications

  8. Instrument Panel Knee Bolster Deflector (2) » Install

  9. Instrument Panel Driver Knee Bolster Brace Bolt (1) » Install and tighten [4x] — Fastener Specifications

  10. Data Link Connector (2) » Install

  11. Data Link Connector Bolt (1) » Install and tighten [2x] — Fastener Specifications

  12. Instrument Panel Carrier (1) » Install — Instrument Panel Carrier Replacement

  13. {with C3A} Ground terminal (4) » Install 43.1. Connect the electrical connector. (3) 43.2. Ground Nut (2) » Install and tighten — Fastener Specifications

  14. Instrument Panel Lower Trim Panel Insulator (1) » Install

  15. Instrument Panel Lower Insulator Retainer (1) » Install [3x]

  16. Clean the left and right side windshield wiper transmission pivot shaft splines with a soft wire brush before installing the windshield wiper arm.

  17. Starting at the front of the right front side door sill garnish molding (1) engage the 2 retaining clips on the forward vertical wall.

  18. Work your way rearward engaging all the right front side door sill garnish molding retaining clips.

  19. Front Side Door Sill Garnish Molding - Right Side (1) » Install

  20. Windshield Wiper System Module Shield (1) » Install

  21. Air Inlet Grille Panel (2) » Install

  22. Windshield Washer Nozzle Hose » Connect [3x]

  23. Air Inlet Grille Panel Retainer (1) » Install [8x]

  24. Hood Rear Outer Air Inlet Seal (2) » Install [2x]

  25. Hood Rear Outer Air Inlet Seal Retainer (1) » Install [2x]

  1. Air Inlet Grille Panel Extension (1) » Install [2x]
  2. Remove the double layer of masking tape around the perimeter of the painted surfaces.
  3. Using a 50/50 mixture of isopropyl alcohol and clean drinkable water with a clean towel, remove any left over adhesive residue from the masking tape.
  4. Connect the negative battery cable. Battery Negative Cable Disconnection and Connection
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 29
Heater and Air Conditioning Evaporator and Blower Module Removal and Installation — figure 29

  1. Align the windshield wipers to their respective alignment circles (1)  on the windshield.

  2. Windshield Wiper Arm (3) » Install [2x]

  3. Windshield Wiper Arm Nut (2) » Install and tighten [2x] — Fastener Specifications

  4. Lubricate the windshield with clean washer fluid.

  5. Run the windshield wipers for two complete cycles then turn off the windshield wipers.

  6. Ensure the windshield wipers are in the full park position.

  7. If alignment is required, remove the windshield wiper arms and repeat steps 60 through 66 to achieve the proper windshield wiper (3) alignment.

  8. Windshield Wiper Arm Finish Cap (1) » Install [2x]

  9. Fill the cooling system. Cooling System Draining and Filling

  10. Recharge the refrigerant. Refrigerant Recovery and Recharging

  11. Inspect for refrigerant leaks.

  12. Inspect for coolant leaks.