GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2001 🢒 L100/L200/LW200 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Suction Pipe Replacement

Removal Procedure

    Object Number: 896381 Size: SH
  1. Disconnect the negative battery cable.

    2. Important: Verifying the purity of the refrigerant with a purity identifier before recovery is recommended.

  2. Recover refrigerant using an approved refrigerant recovery system. Measure the amount of oil removed during recovery and record.
  3. Remove the air box from the rail.

    4. Object Number: 893628 Size: SH
  4. Remove the suction/liquid line assembly clamp fastener at the engine mount area.

    5. Object Number: 892740 Size: SH
  5. Disconnect the high pressure sensor electrical connector.

    6. Caution: Refer to HVAC Compressor Lines/Hoses Caution in the Preface section.


    Object Number: 892706 Size: SH
  6. Remove suction/liquid line assembly to liquid line nut and remove.
  7. Install the cap on the liquid line to prevent dirt and moisture entry.

    8. Caution: Refer to Vehicle Lifting Caution in the Preface section.


    Object Number: 894225 Size: SH
  8. Raise the vehicle.
  9. Remove the lower cradle splash shield to cradle and wheelhouse fasteners and remove the splash shield.

    10. Object Number: 892729 Size: SH
  10. Remove the suction/liquid line assembly to suction pipe nut and remove.

    11. Object Number: 892741 Size: SH
  11. Remove the suction/liquid line assembly to horn bracket clamp.

    12. Object Number: 893630 Size: SH
  12. Remove the suction/liquid line assembly clamp fastener at the rail.
  13. Lower the vehicle.

    14. Object Number: 892744 Size: SH
  14. Remove the suction/liquid line assembly to thermal expansion valve (TXV) bolt at front of dash and remove the block from the TXV.
  15. Install the cap on the TXV to prevent dirt and moisture entry.

    16. Object Number: 893631 Size: SH
  16. Remove the suction/liquid line assembly from the clamp at front of dash.
  17. Remove the O2 sensor clip from the suction/liquid line assembly.
  18. Remove the harness bracket from the cowl nut open harness clip (steel).

    19. Object Number: 894479 Size: SH
  19. Remove the suction/liquid line assembly from the vehicle.

    20. Object Number: 894470 Size: SH
  20. Remove pressure transducer from suction/liquid line assembly.

Installation Procedure

    Notice: Refer to Refrigerant Oil Notice in the Preface section.

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 894459 Size: SH
  1. Install the pressure transducer to the suction/liquid line assembly.

    2. Tighten
    Tighten the transducer to 7 N·m (62 lb in).


    Object Number: 894479 Size: SH
  2. Position the suction/liquid line assembly into vehicle around the engine mount with the liquid line inside of the wiring harness and outside of the fuel lines.
  3. Position the suction liquid line rearward of the wiring harness at the front of the dash with the oxygen sensor harness behind the lineset.

    4. Notice: Refer to Refrigerant Oil Notice in the Preface section.


    Object Number: 892744 Size: SH

    Important: Always install new O-rings to prevent refrigerant leaks.

  4. Remove the shipping caps from the thermal expansion valve (TXV) and the suction/liquid line assembly.
  5. Lubricate the suction/liquid line assembly to TXV O-rings.
  6. Position the suction/liquid line assembly to the TXV and hand start the bolt.

    7. Tighten
    Tighten the bolt to 77 N·m (62 lb in).


    Object Number: 892706 Size: SH
  7. Remove the shipping cap from the suction/liquid line assembly and from the liquid line.
  8. Add any PAG oil that was removed during recovery to liquid line.

    9. Important: Always install new seal washers to prevent refrigerant leaks.

  9. Install the seal washer and install the suction/liquid line assembly to the liquid line and hand start the nut.

    10. Tighten
    Tighten the nut to 12 N·m (106 lb in).


    Object Number: 893631 Size: SH
  10. Install the suction/liquid line assembly into the clamp at the front of the dash.
  11. Install the oxygen sensor harness clip onto the suction/liquid line assembly.
  12. Close the steel harness clip and install the nut.

    13. Tighten
    Tighten the nut to 6 N·m (53 lb in).


    Object Number: 893628 Size: SH
  13. Install the suction/liquid line assembly clamp at the mount area.

    14. Tighten
    Tighten the nut to 5 N·m (44 lb in).

    Caution: Refer to Vehicle Lifting Caution in the Preface section.


    Object Number: 892729 Size: SH
  14. Raise the vehicle.
  15. Lubricate the seal washer and install the suction/liquid line assembly to the suction pipe and hand start the nut.

    16. Tighten
    Tighten the nut to 12 N·m (106 lb in).


    Object Number: 892741 Size: SH
  16. Install the suction/liquid line assembly clamp to the horn bracket.

    17. Tighten
    Tighten the nut to 10 N·m (89 lb in).


    Object Number: 893630 Size: SH
  17. Install the suction/liquid line assembly clamp at the rail and install the nut.

    18. Tighten
    Tighten the nut to 5 N·m (44 lb in).


    Object Number: 894225 Size: SH
  18. Install the lower cradle splash shield by sliding the shield (1) between the wheelhouse liner (2) and the wheelhouse (3).
  19. Install the splash shield to the wheelhouse and cradle fasteners.

    20. Tighten
    Tighten the fasteners to 5 N·m (44 lb in).


    Object Number: 892740 Size: SH
  20. Lower the vehicle.
  21. Install the high pressure sensor electrical connector.

    22. Object Number: 896381 Size: SH
  22. Install the air box.
  23. Connect the negative battery cable.

    24. Tighten
    Tighten the battery terminal bolts to 17 N·m (13 lb ft).

  24. Evacuate, charge, and leak check the A/C system.