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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 505 (HVAC SYSTEM - MANUAL)REPAIR INSTRUCTIONSRECIRCULATION ACTUATOR REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 GMC Savana Special, 2009 GMC Savana Camper Special, 2009 GMC Savana, 2009 Chevrolet RV Cutaway, and 2009 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of recirculation door actuator
    GM1874385Courtesy of GENERAL MOTORS CORP.
  1. Install the recirculation door actuator (5) to the linkage (3).
  2. Install the actuator into mounting position (2) and attach vacuum line (4).
    NOTE: Ensure the recirculation door (1) operates without binding and seals properly.
  3. Reposition the accumulator for installation.
    4. Fig 2: View Of evaporator and blower module assembly cover
    GM1874383Courtesy of GENERAL MOTORS CORP.
  4. Install the evaporator and blower module assembly cover (2) to evaporator case (3).
    5. CAUTION: Refer to Fastener Caution .
  5. Secure cover with the fourteen screws (1) and tighten to 1.9 N.m (17 lb in).
  6. Install new sealing washers to the evaporator inlet and outlet tubes. Refer to Sealing Washer Replacement .
    7. Fig 3: View Of A/C System Evaporator And Components
    GM800358Courtesy of GENERAL MOTORS CORP.
  7. Install the evaporator inlet tube (4) to the evaporator (5).
  8. Install the evaporator inlet tube retaining nut (3) and tighten to 16 N.m (12 lb ft).
    9. Fig 4: View Of A/C System Components
    GM769765Courtesy of GENERAL MOTORS CORP.
  9. Install the evaporator outlet hose and retaining nuts (4,5) and tighten to 18 N.m (13 lb ft).
  10. Connect the low pressure sensor electrical connector.
  11. Connect the blower motor electrical connector.
  12. Connect the blower motor resistor assembly electrical connector.
  13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  14. Leak test the fittings of the repaired or replaced component using the J 39400-A  .
  15. Install the battery. Refer to Battery Replacement (Primary) .
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.