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For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Cobalt 🢒 Engine 🢒 Engine Electrical 🢒 Air Conditioning Compressor Hose Replacement

Air Conditioning Compressor Hose Replacement RPO LSJ

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

    2. Object Number: 1403001 Size: SH
  2. Remove the compressor hose from the evaporator hose.
  3. Remove and discard the seal washer.
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

    5. Object Number: 1388246 Size: SH
  5. Remove the mounting cover from the charge air cooler pump and position the pump forward.

    6. Object Number: 872571 Size: SH
  6. Disconnect the electrical connector from the pressure transducer.

    7. Object Number: 865182 Size: SH
  7. Remove the compressor and condenser hose assembly bolt from the compressor.
  8. Remove the compressor and condenser hose assembly from the compressor.
  9. Remove and discard the sealing washers.

    10. Object Number: 872545 Size: SH
  10. Remove the compressor hose from the condenser.
  11. Remove and discard the seal washer.

Installation Procedure
  1. Route the compressor hose to the evaporator hose.

    2. Object Number: 865182 Size: SH
  2. Install new sealing washers on the compressor and condenser hose fittings. Refer to Sealing Washer Replacement .
  3. Install the A/C compressor and condenser hose assembly to the compressor.

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

  4. Install the A/C compressor and condenser hose assembly bolt.

    5. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 872545 Size: SH
  5. Install a new seal washer to the compressor hose. Refer to Sealing Washer Replacement .
  6. Install the compressor hose and bolt to the condenser.

    7. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 872571 Size: SH
  7. Connect the pressure transducer electrical connector.

    8. Object Number: 1388246 Size: SH
  8. Install the charge cooler pump.

    9. Tighten
    Tighten the bolts to 10 N·m (88 lb in).

  9. Lower the vehicle.

    10. Object Number: 1403001 Size: SH
  10. Install a new seal washer to the compressor hose. Refer to Sealing Washer Replacement .
  11. Install the compressor hose and nut to the evaporator hose.

    12. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

  12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  13. Leak test the fittings using the J 39400-A .

Air Conditioning Compressor Hose Replacement L61, LE5

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.

    3. Object Number: 872571 Size: SH
  3. Disconnect the electrical connector from the pressure transducer.

    4. Object Number: 865182 Size: SH
  4. Remove the compressor and condenser hose assembly bolt from the compressor.
  5. Remove the compressor and condenser hose assembly from the compressor.
  6. Remove and discard the sealing washers.

    7. Object Number: 872545 Size: SH
  7. Remove the compressor hose from the condenser.
  8. Remove and discard the seal washer.
  9. Lower the vehicle.

    10. Object Number: 872544 Size: SH
  10. Remove the compressor hose from the evaporator hose.
  11. Remove and discard the seal washer.

Installation Procedure

    Object Number: 865182 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install new sealing washers on the compressor and condenser hose fittings. Refer to Sealing Washer Replacement.
  2. Install the A/C compressor and condenser hose assembly to the compressor.
  3. Install the A/C compressor and condenser hose assembly bolt.

    4. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 872544 Size: SH
  4. Install new seal washer to the compressor hose. Refer to Sealing Washer Replacement.
  5. Install the compressor hose and nut to the evaporator hose.

    6. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

  6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.

    7. Object Number: 872545 Size: SH
  7. Install new seal washer to the compressor hose. Refer to Sealing Washer Replacement.
  8. Install the compressor hose and bolt to the condenser.

    9. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 872571 Size: SH
  9. Connect the pressure transducer electrical connector.
  10. Lower the vehicle.
  11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
  12. Leak test the fittings using the J 39400-A .