GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Cobalt 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Air Conditioning Evaporator Hose Assembly Replacement

Air Conditioning Evaporator Hose Assembly Replacement L61, LE5 - 1st Design

Special Tools

J 39400-A Halogen Leak Detector

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

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

    4. Object Number: 872539 Size: SH
  4. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
  5. Remove and discard the seal washers.

Installation Procedure

    Object Number: 872539 Size: SH
  1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to Sealing Washer Replacement.
  2. Install the condenser tube and evaporator hose to the TXV.

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

  3. Install the TXV nut.

    4. Tighten
    Tighten the nut 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. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
  7. Leak test the fittings using the J 39400-A .

Air Conditioning Evaporator Hose Assembly Replacement LNF

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.

    3. Object Number: 2044592 Size: SH
  3. Remove the compressor hose nut (1) from the evaporator hose.
  4. Remove and discard the seal washer.

    5. Object Number: 872539 Size: SH
  5. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
  6. Remove and discard the seal washers.

Installation Procedure

    Object Number: 872539 Size: SH
  1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to Sealing Washer Replacement.
  2. Install the condenser tube and evaporator hose to the TXV.

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

  3. Install the TXV nut.

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


    Object Number: 2044592 Size: SH
  4. Install new seal washer to the compressor hose. Refer to Sealing Washer Replacement.
  5. Install the compressor hose and nut (1) to the evaporator hose.

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

  6. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement
  7. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
  8. Leak test the fittings using the J 39400-A .