Chevrolet Cobalt Service & Repair Manual: Air Conditioning Refrigerant Line R&R

Compressor Hose

Caution: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
1. Recover refrigerant.
2. Remove charge air cooler outlet pipe.
3. Raise vehicle.
4. Disconnect electrical connector from pressure transducer, Fig. 1.
5. Remove compressor and condenser hose assembly bolt from compressor, Fig. 2.
6. Remove compressor and condenser hose assembly from compressor, Fig. 2.
7. Remove and discard sealing washers, Fig. 2.
8. Remove compressor hose from condenser, Fig. 3.
9. Remove and discard seal washer, Fig. 3.
10. Lower vehicle.
11. Remove compressor hose nut (1) from evaporator hose, Fig. 4.
12. Remove wiring harness from compressor hose bracket, Fig. 4.
13. Remove bolt (2) from compressor hose bracket, Fig. 4.
14. Remove and discard seal washer, Fig. 4.
15. Reverse procedure to install, noting following:
  a. Install new sealing washers on compressor and condenser hose fittings.
  b. Install A/C compressor and condenser hose assembly bolt. Torque bolt to 15 ft. lbs.
  c. Install new seal washer to compressor hose.
  d. Install compressor hose and nut to evaporator hose. Torque nut to 15 ft. lbs.
  e. Install bolt from compressor hose bracket. Torque nut to 15 ft. lbs.
  f. Install new seal washer to compressor hose.
  g. Install compressor hose and bolt to condenser. Torque bolt to 15 ft. lbs.
  h. Evacuate and charge refrigerant system.
  i. Leak test fittings using halogen leak detector tool No. J-39400-A, or equivalent.

Evaporator Hose

1. Remove charge air cooler inlet pipe.
2. Recover refrigerant.
3. Remove compressor hose nut (1) from evaporator hose, Fig. 5.
4. Remove and discard seal washer, Fig. 5.
5. Remove condenser tube and evaporator hose from Thermal Expansion Valve (TXV), Fig. 6.
6. Remove and discard seal washers, Fig. 6.
7. Reverse procedure to install, noting following:
  a. Install new sealing washers on condenser tube and evaporator hose fittings.
  b. Install TXV nut. Torque nut to 15 ft. lbs.
  c. Install new seal washer to compressor hose.
  d. Install compressor hose and nut to evaporator hose. Torque nut to 15 ft. lbs.
  e. Evacuate and charge refrigerant system.
  f. Leak test fittings using halogen leak detector tool No. J-39400-A, or equivalent.

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

    Air Conditioning Compressor Clutch Transfer
    Refer to Fig. 1 when performing the following procedure. 1. Recover the refrigerant. 2. Remove the air cleaner assembly. ...

    Air Conditioning System Leak, Inspection
    A visual inspection must always be performed to confirm the presence of aftermarket components, potential collision damage, or areas of concern. With the oils used for R12 systems, ...

    See also:

    Chevrolet Cobalt Owners Manual. Engine Air Cleaner/Filter (2.2L Engine)
    See Engine Compartment Overview for the location of the engine air cleaner/filter. When to Inspect the Engine Air Cleaner/Filter Inspect the air cleaner/filter at the Maintenance II intervals and replace it at the first oil change after each 50,000 mile (80 000 km) interval. See Scheduled Mai ...

    Chevrolet Cobalt Owners Manual

    Chevrolet Cobalt Service Manual


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