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HOMESERVICE MANUALSCHEVROLET2003S10 PICKUP 2D PICKUP, 2.2 H, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 240 (HEATING, VENTILATION AND AIR CONDITIONING)REPAIR INSTRUCTIONSLIQUID LINE REPLACEMENTINSTALLATION PROCEDURE
2003 Chevrolet S10 Pickup 2D Pickup, 2.2 H, Automatic

Installation Procedure

2003 Chevrolet S10 Pickup 2D Pickup, 2.2 H, AutomaticSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Liquid Line, Nut & Receiver Dehydrator
    GM932365Courtesy of GENERAL MOTORS CORP.
  1. Remove protective cap from RD and RD end of liquid line and install new seal washer. Refer to Sealing Washer Replacement .
  2. Feed RD end of liquid line down front of shock tower, beneath the surge return hose and under negative battery cable and battery box.
  3. From headlamp opening guide RD end of liquid line to RD fitting and install nut.
    4. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install liquid line nut using a large pair of pliers hold fitting while tightening. Be careful not to twist line.

    Tighten:  Tighten the nut to 16 N.m (12 lb ft).

    5. Fig 2: Liquid Line, Nut & TXV
    GM931930Courtesy of GENERAL MOTORS CORP.
  5. Remove protective cap from TXV and TXV end of liquid line, install new seal washers. Refer to Sealing Washer Replacement .
  6. Install liquid line to TXV with nut.

    Tighten:  Tighten the nut to 16 N.m (12 lb ft).

    7. Fig 3: Liquid Line, Strut Tower & Nut
    GM932360Courtesy of GENERAL MOTORS CORP.
  7. Install liquid line P-clip and nut to the shock tower cap stud.

    Tighten:  Tighten the nut to 8 N.m (71 lb in).

    8. Fig 4: Clipping EPS Harness To Liquid Line
    GM932504Courtesy of GENERAL MOTORS CORP.
  8. Clip EPS harness to liquid line.
  9. Clip PTU vent hose to liquid line.
    10. Fig 5: Heater Outlet Hose Clamp & Surge Tank
    GM931349Courtesy of GENERAL MOTORS CORP.
  10. Install surge tank and bolts.

    Tighten:  Tighten the bolt to 6 N.m (53 lb in).

  11. Install left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement in Lighting Systems.
  12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  13. Leak test the fittings using the J 39400-A  . See Special Tools .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.