GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu Classic 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Air Conditioning Compressor Hose Replacement

Air Conditioning Compressor Hose Replacement L61

Special Tools

J 39400-A Halogen Leak Detector

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

    2. Object Number: 1201941 Size: SH
  2. Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs.
  3. Remove the compressor hose and suction line connector.
  4. Remove the compressor hose from the suction line.
  5. Remove and discard the O-rings.

    6. Object Number: 1201967 Size: SH
  6. Remove the compressor hose bracket bolt.
  7. Remove the air cleaner intake duct from the air cleaner assembly. Refer to Air Cleaner Outlet Resonator Replacement .
  8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

    9. Object Number: 1203534 Size: SH
  9. Remove the right front fender liner. Refer to Front Fender Liner Replacement .
  10. Remove the right radiator air deflector retainers.
  11. Remove the right radiator air deflector.

    12. Object Number: 1201921 Size: SH
  12. Remove the liquid line and compressor hose bolt from the condenser.
  13. Remove the compressor hose from the condenser.

    14. Object Number: 1201972 Size: SH
  14. Remove the compressor hose nut from the compressor.
  15. Remove the compressor hose from the compressor.

    16. Object Number: 1201978 Size: SH
  16. Remove the compressor hose from the rail clip.

    17. Object Number: 1201981 Size: SH
  17. Remove the compressor line.

    18. Important: Cap all A/C components immediately to prevent system contamination.

  18. Remove and discard the sealing washers.

Installation Procedure
  1. Uncap A/C components.
  2. Install new sealing washers. Refer to Sealing Washer Replacement .

    3. Object Number: 1201981 Size: SH
  3. Install the compressor line.

    4. Object Number: 1201978 Size: SH
  4. Install the compressor hose to the rail clip.
  5. Install the compressor hose to the compressor.

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


    Object Number: 1201972 Size: SH
  6. Install the compressor hose nut to the compressor.

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


    Object Number: 1201921 Size: SH
  7. Install the compressor hose to the condenser.
  8. Install the liquid line and compressor hose bolt to the condenser.

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

    Important: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.


    Object Number: 1203534 Size: SH
  9. Install the right radiator air deflector.
  10. Install the right radiator air deflector retainers.
  11. Install the right front fender liner. Refer to Front Fender Liner Replacement .
  12. Lower the vehicle.
  13. Install the air cleaner intake duct to the air cleaner assembly. Refer to Air Cleaner Outlet Resonator Replacement .
  14. Install new O-rings. Refer to O-Ring Replacement .

    15. Object Number: 1201941 Size: SH
  15. Install the compressor hose to the suction line.
  16. Install the compressor hose and suction line connector.

    17. Object Number: 1201967 Size: SH
  17. Install the compressor hose bracket bolt.

    18. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  18. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  19. Leak test the fitting using the J 39400-A .

Air Conditioning Compressor Hose Replacement LZ4


Object Number: 1686547 Size: MF

Callout

Component Name

Preliminary Procedure

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Remove the right front fender liner. Refer to Front Fender Liner Replacement .

1

A/C Compressor and Condenser Connector

Procedure

  1. Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs.
  2. Remove the A/C compressor hose from the evaporator hose assembly and discard O-rings. Refer to O-Ring Replacement .

2

A/C Compressor Hose Nut

Notice: Refer to Fastener Notice in the Preface section.

Tip
Remove the A/C compressor hose from the A/C compressor and cap hose.

Tighten
20 N·m (15 lb ft)

3

Sealing Washer

Tip
Remove and discard sealing washers. Refer to Sealing Washer Replacement .

4

A/C Compressor Hose Bolt

Tighten
20 N·m (15 lb ft)

5

Sealing Washer

Tip
Remove and discard sealing washers. Refer to Sealing Washer Replacement .

6

A/C Compressor Hose Assembly

Procedure

  1. Note routing of the A/C compressor hose to ensure proper routing.
  2. Using J 39400 leak test A/C compressor hose connections.

Special Tools

J 39400 Electronic Halogen Leak Detector