Chevrolet Cobalt Service & Repair Manual: Refrigerant Line O-Ring, Replace

Caution: Air conditioning R-134a liquid refrigerant is capable of harming eyes or freezing skin. Always wear safety goggles and avoid contact with liquid refrigerant. Failure to follow these instructions may result in serious personal injury.
Caution: Air conditioning R-134a refrigerant gas is capable of displacing the air required for breathing in a confined space and can produce toxic gasses if burned at high temperatures. Do not release a large quantity of R-134a gas within a confined space or allow it to be exposed to a high temperature flame (such as a torch). Consult the Material Safety Data Sheet for further information. Failure to follow these instructions may result in serious personal injury or death.
Caution: Use extreme care and observe all safety and service precautions related to the use of refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to follow these instructions may result in serious personal injury.
Any time air conditioning components are removed the O-rings need to be replaced.
Do not reuse air conditioning O-ring seals.

Removal

1. Disassemble A/C refrigerant components, as required.
2. For compression style fittings, use a back-up wrench on fitting (2) and loosen fitting nut (1), Fig. 1.
3. For banjo style fittings, remove bolt retaining banjo type fitting.
4. Remove O-ring seal from A/C refrigerant component.
5. Inspect O-ring seal for signs of damage. Inspect A/C refrigerant components for damage or burrs.
6. Cap or tape A/C refrigerant components immediately to prevent system contamination.
7. Discard O-ring seal.

Installation

Do not allow any of the refrigerant oil on new O-ring seal to enter refrigerant system.
Do not reuse O-ring seals.
1. Inspect new O-ring seal for any sign of cracks, cuts, or damage.
2. Remove cap or tape from A/C refrigerant components.
3. Carefully clean sealing surfaces of A/C refrigerant components using a lint free clean, dry cloth.
4. Lightly coat new O-ring seal with refrigerant oil.
5. Carefully slide new O-ring seal (1) onto A/C refrigerant component, Fig. 2. O-ring seal must be fully seated.
6. Assemble A/C components, as required.

Fig. 1 Compression fitting nut removal

Fig. 2 A/C refrigerant component O-ring seal installation

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