GM Service Manual Online
For 1990-2009 cars only

Suction Hose Replacement 3.6L Engine

Special Tools

J 39400-A Halogen Leak Tester

Removal Procedure

    Note: With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the vacuum brake booster power reserve.

  1. Deplete the vacuum brake booster power reserve.
  2. Warning: Refer to Safety Glasses Warning in the Preface section.

  3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  4. Warning: Refer to Battery Disconnect Warning in the Preface section.

  5. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  6. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement.
  7. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.

  8. Object Number: 1957941  Size: SH

    Note: The left engine cover has one front and one rear outer retaining clip.

    Note: Grasp and pry the left engine cover (1) upwards to detach the left engine cover (1) from the outer retaining clip (2).

  9. Detach the left engine cover (1) from the outer retaining clip (2).

  10. Object Number: 1957942  Size: SH

    Note: Disengage the left engine cover (1) from the ball stud (2) by pulling up firmly on the rear and front of the left engine cover (1).

  11. Detach the left engine cover (1) from the ball stud (2).
  12. Remove the left engine cover (1).

  13. Object Number: 2040644  Size: SH
  14. Disconnect the vacuum hose (1) and the vacuum brake booster check valve (3) from the vacuum brake booster (2).
  15. Detach the vacuum hose (1) from the bulkhead mounted vacuum hose retaining bracket (4) and position aside.

  16. Object Number: 2040645  Size: SH
  17. Remove the left engine cover mounting bracket to cylinder head retaining bolt (3).
  18. Remove the left engine cover mounting bracket (1) from the cylinder head (2).

  19. Object Number: 2034102  Size: SH
  20. Remove the remote battery positive post cover (1).

  21. Object Number: 2040647  Size: SH
  22. Remove the remote battery positive post to wiring harness retaining bolt (1).
  23. Remove the starter motor power cable (2) and position aside.

  24. Object Number: 1957871  Size: SH
  25. Remove the suction pipe upper to suction pipe lower retaining nut (1).

  26. Object Number: 1955641  Size: SH
  27. Remove the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
  28. Detach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).

  29. Object Number: 1950845  Size: SH
  30. Disconnect the suction pipe upper (1) from the suction pipe lower (2).
  31. Note: The sealing washer (3) is a single use item and must be discarded after use.

  32. Remove the sealing washer (3). Refer to Sealing Washer Replacement.
  33. Discard the sealing washer

    Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

  34. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).

  35. Object Number: 2040648  Size: SH
  36. Detach the suction pipe (2) and the liquid pipe (3) from the suction pipe/liquid pipe retaining clip (1).

  37. Object Number: 2040649  Size: SH
  38. Remove the suction pipe/liquid pipe pad to TX valve retaining nut (1).

  39. Object Number: 2040651  Size: SH
  40. Disconnect the suction pipe/liquid pipe pad (3) from the TX valve (1).
  41. Note: The sealing washers (2) are a single use item and must be discarded after use.

  42. Remove the sealing washers (2). Refer to Sealing Washer Replacement.
  43. Discard the sealing washers

    Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

  44. Cap or plug the suction pipe (4), liquid pipe (5) and the TX valve (1).
  45. Remove the liquid pipe (5) from the suction pipe/liquid pipe pad (3).
  46. Remove the suction pipe/liquid pipe pad (3) from the engine compartment.

Installation Procedure


    Object Number: 2040651  Size: SH
  1. Install the liquid pipe (5) to the suction pipe/liquid pipe pad (3).
  2. Remove the plugs or caps from the suction pipe (4), liquid pipe (5) and the TX valve (1).
  3. Note: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

  4. Install NEW sealing washers (2). Refer to Sealing Washer Replacement.
  5. Position the suction pipe/liquid pipe pad (3) to the TX Valve (1).
  6. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 2040649  Size: SH
  7. Install the suction pipe/liquid pipe pad to TX valve retaining nut (1) and tighten to 22 N·m(16 lb ft).

  8. Object Number: 1957873  Size: SH
  9. Remove the plugs or caps from the suction pipe upper (1) and the suction pipe lower (2).
  10. Note: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

  11. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement.
  12. Install the suction pipe upper (1) to the suction pipe lower (2).

  13. Object Number: 1955641  Size: SH
  14. Attach the liquid pipe (1) to the suction pipe/liquid pipe retaining clip (2).
  15. Install the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).

  16. Object Number: 1957875  Size: SH
  17. Install the suction pipe upper to suction pipe lower retaining nut (1) and tighten to 22 N·m(16 lb ft).

  18. Object Number: 2040647  Size: SH
  19. Install the starter motor positive cable (2) to the remote battery positive post.
  20. Install the remote battery positive post to wiring harness retaining bolt (1) and tighten to 15 N·m (11 lb ft).

  21. Object Number: 2034102  Size: SH

    Note: Make sure the clips on the remote battery positive post cover (1) are engaged to avoid an induced rattle condition.

  22. Install the remote battery positive post cover (1).

  23. Object Number: 2040648  Size: SH
  24. Attach the suction pipe (2) and the liquid pipe (3) to the suction pipe/liquid pipe retaining clip (1).

  25. Object Number: 2040644  Size: SH
  26. Connect the vacuum hose (1) and the vacuum brake booster check valve (3) to the vacuum brake booster (2).
  27. Attach the vacuum hose (1) to the bulkhead mounted vacuum hose retaining bracket (4).

  28. Object Number: 2040645  Size: SH
  29. Install the left engine cover mounting bracket (1) to the cylinder head (2).
  30. Install the left engine cover mounting bracket to cylinder head retaining bolt (3) and tighten to 35 N·m (26 lb in).

  31. Object Number: 1957942  Size: SH
  32. Position the left engine cover (1) over the intake manifold so the grommet is aligned with the ball stud (2).
  33. Note : Press the left engine cover (1) down firmly near the ball stud to attach the left engine cover (1) to the ball stud (2).

  34. Attach the left engine cover (1) to the ball stud (2).

  35. Object Number: 1957941  Size: SH

    Note: The left engine cover has one front and one rear outer retaining clip.

    Note: Press the left engine cover (1) down firmly near the outer retaining clips to attach the left engine cover (1) to the outer retaining clip (2).

  36. Attach the left engine cover (1) to the outer retaining clip (2).
  37. Install the cross car brace, if fitted. Refer to Front End Panel Module Carrier Assembly Replacement.
  38. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
  39. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement.
  40. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  41. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
  42. Leak test the fittings of the component using electronic leak detector.

Suction Hose Replacement 6.0L Engine

Special Tools

J 39400-A Halogen Leak Tester

Removal Procedure

    Warning: Refer to Safety Glasses Warning in the Preface section.

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  2. Warning: Refer to Battery Disconnect Warning in the Preface section.

  3. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  4. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement.
  5. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
  6. Remove the engine cover. Refer to Engine Cover Replacement.

  7. Object Number: 2040644  Size: SH
  8. Disconnect the vacuum hose (1) and the vacuum brake booster check valve (3) from the vacuum brake booster (2).
  9. Detach the vacuum hose (1) from the bulkhead mounted vacuum hose retaining bracket (4) and position aside.

  10. Object Number: 2034102  Size: SH
  11. Remove the remote battery positive post cover (1).

  12. Object Number: 2040647  Size: SH
  13. Remove the remote battery positive post to wiring harness retaining bolt (1).
  14. Remove the starter motor power cable (2) and position aside.

  15. Object Number: 1957871  Size: SH
  16. Remove the suction pipe upper to suction pipe lower retaining nut (1).

  17. Object Number: 1955641  Size: SH
  18. Remove the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
  19. Detach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).

  20. Object Number: 1950845  Size: SH
  21. Disconnect the suction pipe upper (1) from suction pipe lower (2).
  22. Note: The sealing washer (3) is a single use item and must be discarded after use.

  23. Remove the sealing washer (3). Refer to Sealing Washer Replacement.
  24. Discard the sealing washer

    Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

  25. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).

  26. Object Number: 2040967  Size: SH
  27. Detach the suction pipe (2) and the liquid pipe (3) from the suction pipe/liquid pipe retaining clip (1).

  28. Object Number: 2040968  Size: SH
  29. Remove the suction pipe/liquid pipe pad to TX Valve retaining nut (1).

  30. Object Number: 2040969  Size: SH
  31. Disconnect the suction pipe/liquid pipe pad (3) from the TX valve (1).
  32. Note: The sealing washers (2) are a single use item and must be discarded after use.

  33. Remove the sealing washers (2). Refer to Sealing Washer Replacement.
  34. Discard the sealing washers

    Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

  35. Cap or plug the suction pipe (4), liquid pipe (5) and the TX valve (1).
  36. Remove the liquid pipe (5) from the suction pipe/liquid pipe pad (3).
  37. Remove the suction pipe/liquid pipe pad (3) from the engine compartment

Installation Procedure


    Object Number: 2040969  Size: SH
  1. Install the liquid pipe (5) to the suction pipe/liquid pipe pad (3).
  2. Remove the plugs or caps from the suction pipe (4), liquid pipe (5) and the TX valve (1).
  3. Note: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

  4. Install NEW sealing washers (2). Refer to Sealing Washer Replacement.
  5. Position the suction pipe/liquid pipe pad (3) to the TX Valve (1).
  6. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 2040968  Size: SH
  7. Install the suction pipe/liquid pipe pad to TX valve retaining nut (1) and tighten to 22 N·m (16 lb ft).

  8. Object Number: 1957873  Size: SH
  9. Remove the plugs or caps from the suction pipe upper (1) and the suction pipe lower (2).
  10. Note: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

  11. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement.
  12. Install the suction pipe upper (1) to the suction pipe lower (2).

  13. Object Number: 1955641  Size: SH
  14. Attach the liquid pipe (1) to the suction pipe/liquid pipe retaining clip (2).
  15. Install the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3) and tighten to 22 N·m (16 lb ft).

  16. Object Number: 1957875  Size: SH
  17. Install the suction pipe upper to suction pipe lower retaining nut (1) and tighten to 22 N·m(16 lb ft).

  18. Object Number: 2034103  Size: SH
  19. Install the starter motor positive cable (2) to the remote battery positive post (3).
  20. Install the remote battery positive post to wiring harness retaining bolt (1) and tighten to 15 N·m (11 lb ft).

  21. Object Number: 2034102  Size: SH

    Note: Make sure the clips on the remote battery positive post cover (1) are engaged to avoid an induced rattle condition.

  22. Install the remote battery positive post cover (1).

  23. Object Number: 2040967  Size: SH
  24. Attach the suction pipe (2) and the liquid pipe (3) from the suction pipe/liquid pipe retaining clip (1).

  25. Object Number: 2040644  Size: SH
  26. Connect the vacuum hose (1) and the vacuum brake booster check valve (3) to the vacuum brake booster (2).
  27. Attach the vacuum hose (1) to the bulkhead mounted vacuum hose retaining bracket (4).
  28. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
  29. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement.
  30. Install the engine cover. Refer to Engine Cover Replacement.
  31. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  32. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
  33. Leak test the fittings of the component using J 39400-A .