GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 O-Ring Replacement

Removal Procedure

    Object Number: 297225 Size: SH
  1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure.
    2. • For compression style fittings, use a back up wrench on the fitting (2) and loosen the fitting nut (1).
    • For banjo style fittings, remove the bolt retaining the banjo type fitting.
  2. Remove the O-ring seal from the A/C refrigerant component.
  3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.
  4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.

    5. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.

  5. Cap or tape the A/C refrigerant components.
  6. Discard the O-ring seal.

Installation Procedure
  1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
  2. Remove the cap or tape from the A/C refrigerant components.
  3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.

    4. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system.

  4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.

    5. Important: DO NOT reuse O-ring seals.

  5. Carefully slide the new O-ring seal onto the A/C refrigerant component.

    6. Object Number: 662315 Size: SH
  6. The O-ring seal must be fully seated.

    7. Object Number: 297225 Size: SH
  7. Assemble the A/C components.

    8. Refer to the appropriate repair procedure.

    • For compression style fittings, use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification.
    • For banjo style fittings, install the bolt retaining the banjo type fitting and tighten to specification.