GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Aveo 🢒 Transmission/Transaxle 🢒 Manual Transmission - Y4M 🢒 Refrigerant Tubes Replacement

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number: 1241535 Size: SH
  1. Disconnect the negative battery cable.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  3. Remove the air cleaner housing bolts and the air filter housing assembly.

    4. Object Number: 1251931 Size: SH
  4. Disconnect the electrical connector at the pressure transducer.

    5. Object Number: 1251935 Size: SH
  5. Remove the liquid evaporator pipe connector block retaining nut at the cowl.

    6. Object Number: 1251941 Size: SH
  6. Remove the liquid pipe connector block to the condenser retaining bolt.

    7. Object Number: 1251942 Size: SH
  7. Remove the refrigerant suction hose to liquid pipe block retaining nut.
  8. Remove the liquid evaporator pipe support clamp bolt.

    9. Object Number: 1251944 Size: SH
  9. Remove the liquid evaporator pipe and the refrigerant suction hose.

    10. Object Number: 1251945 Size: SH
  10. Remove the refrigerant suction hose and the refrigerant discharge hose to compressor connector block retaining nut.

    11. Object Number: 1251946 Size: SH
  11. Remove the refrigerant discharge hose connector block bolt at the condenser.

    12. Object Number: 1251954 Size: SH
  12. Remove the refrigerant discharge hose support clamp bolt.
  13. Remove the refrigerant discharge hose.

Installation Procedure

    Object Number: 1251954 Size: SH
  1. Position the refrigerant suction hose section into the vehicle.
  2. Install a new O-ring on the connector block at the condenser.
  3. Install a new O-ring at the liquid condenser to evaporator plate pipe connector block.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the refrigerant discharge hose support clamp bolt.

    5. Tighten
    Tighten the refrigerant discharge hose support clamp bolt to 7 N·m (62 lb in).


    Object Number: 1251946 Size: SH
  5. Install the refrigerant discharge hose connector block bolt at the condenser.

    6. Tighten
    Tighten the refrigerant discharge hose connector block bolt to 16 N·m (12 lb ft).


    Object Number: 1251945 Size: SH
  6. Install the refrigerant suction hose and the refrigerant discharge hose to compressor connector block retaining nut.

    7. Tighten
    Tighten the refrigerant suction hose and the refrigerant discharge hose to compressor block retaining nut to 33 N·m (24 lb ft).


    Object Number: 1251942 Size: SH
  7. Install the refrigerant suction hose connector block retaining nut.

    8. Tighten
    Tighten the refrigerant suction hose connector block retaining nut to 15 N·m (11 lb ft).


    Object Number: 1251941 Size: SH
  8. Install the liquid pipe connector block to condenser retaining bolt.

    9. Tighten
    Tighten the liquid pipe connector block to condenser retaining bolt to 14 N·m (124 lb in).


    Object Number: 1251935 Size: SH
  9. Install the liquid evaporator pipe connector block retaining nut at the cowl.

    10. Tighten
    Tighten the liquid evaporator pipe connector block retaining nut to 15 N·m (11 lb ft).


    Object Number: 1251931 Size: SH
  10. Connect the electrical connector to the pressure transducer.

    11. Object Number: 1241535 Size: SH
  11. Install the air cleaner housing assembly with the retaining bolts.

    12. Tighten
    Tighten the air cleaner housing assembly retaining bolts to 12 N·m (106 lb in).

  12. Connect the negative battery cable.
  13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .