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http://www.imcool.com/articles/aircondition/fix_vacuum_line.htm This site has a nice response to the problem. Deactivate air bags as directed by auto manual, check Delco stereo antitheft reactivation info, and then disconnect negative battery terminal. You must drop the plastic cover under the dash on the passenger side - leave it hanging. Open the glove box and at the back top edge are two rubber flaps that can be flipped forward to allow the glove box to flop all the way open; you must lift the glove box slightly to flip the rubber flaps forward. The vacuum lines are four color coded plastic lines clearly visable. You can check for vacuum with the engine running as described at the web site above. Unscrew the 7mm nut holding the vacuum lines to the Vacuum controller box and wiggle it off. Mine had a stripped 7mm nut; I had to cut the vacuum lines about four inches from the connector using tin snips. (This actually worked better for me when I reconnected the vacuum hoses as I had 4 inch splices to connect to the inside the box vacuum lines) Remove the HVAC controller box - two 7mm screws. Unplug the large electrical connector by squeezing the orange plug and gently wiggle it out. Remove the electrical connector at the top of box as well. The plastic link at the bottom of the unit can be pulled off the metal cotrol arm and tipped off the Vacuum controller box and set aside. The black box will feed through the glove box with some twisting and turning. Remove the box cover. I noted the color code connections from inside the box to outside and removed the black plastic connector and cut the vacuum lines off. You will need some 1/8 inch interior diameter rubber splices to join the vacuum lines from inside the box to outside. (I tried store bought vacuum connectors the you insert inside the lines, but the vacuum lines were not flexible enough to allow insertion) You essentially completely bypass the factory connectors and make your own splices for a direct connection to the external vacuum lines matching colors that you noted earlier. I used 1/2 inch long rubber insulator from a coax cable - crazy, but it worked. You want something that won't collapse as there is a fair amount of vacuum on the lines. Put it all back together and pat yourself on the back. This fix works on Buick Park Avenues also.

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18y ago

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