GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Discharge Line Replacement

Removal Procedure

    Object Number: 878122 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 the refrigerant using an approved refrigerant recovery system. Measure the amount of oil removed during recovery and record the amount.

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


    Object Number: 894005 Size: SH
  3. Raise the vehicle.

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

  4. Remove the discharge line-to-compressor bolt.
  5. Remove the discharge line and the seal washer from the compressor.
  6. Install caps on the discharge line and the compressor to prevent moisture entry and oil spillage.
  7. Remove the electrical harness clip from the discharge hose.

    8. Object Number: 892723 Size: SH
  8. Remove the discharge line-to-condenser block bolt and remove the discharge line from the block.
  9. Install caps on the discharge line and the condenser block to prevent moisture entry and oil spillage.

    10. Object Number: 892718 Size: SH
  10. Remove the discharge hose clamp screw from the cradle.
  11. Install caps on the discharge line and the condenser block to prevent moisture entry and oil spillage.

Installation Procedure

    Object Number: 892723 Size: SH
  1. Install the discharge hose, the condenser end of line first, flexing the hose to clear the cradle brace.

    2. Important: 

       • Do not lubricate the seal washers.
       • Always install new seal washers to prevent refrigerant leaks.

  2. Remove the discharge line cap and install the new seal washer.
  3. Remove the condenser block cap and install the discharge line.

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

  4. Hand start the discharge line to the condenser block bolt.

    5. Tighten
    Tighten the discharge line-to-condenser block bolt to 20 N·m (15 lb ft).


    Object Number: 892747 Size: SH
  5. Remove the cap from the compressor discharge port.

    6. Important: 

       • Do not lubricate the seal washers.
       • Always install new seal washers to prevent refrigerant leaks.

  6. Remove the cap from the discharge line and install the new seal washer.
  7. Install the discharge line-to-compressor and hand start.

    8. Tighten
    Tighten the discharge line-to-compressor block bolt to 16 N·m (142 lb in).

  8. Snap the electrical harness clip onto the discharge pipe.

    9. Object Number: 892718 Size: SH
  9. Install the discharge line clamp to cradle screw.

    10. Tighten
    Tighten the discharge line clamp fastener-to-cradle to 5 N·m (44 lb in).

  10. Lower vehicle.

    11. Object Number: 878122 Size: SH
  11. Connect the negative battery cable.

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

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