Air Conditioning Compressor Hose Replacement L61

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement in Lighting Systems.



3. Remove the compressor hose nut from the battery box.
4. Remove the compressor hose from the battery box.



5. On L81 vehicles, remove the compressor hose nut from the suction hose jumper.
6. Separate the compressor hose from the suction hose jumper.
7. Install a protective cap to the suction hose jumper to prevent contamination and desiccant saturation.



8. On L61 vehicles, remove the compressor hose nut from the TXV.
9. Remove the compressor hose from the TXV.
10. Install a protective cap to the TXV to prevent contamination and desiccant saturation.



11. Remove the compressor hose nut from the condenser.
12. Remove the compressor hose from the condenser.
13. Install a protective cap to condenser to prevent contamination and desiccant saturation.
14. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



15. Remove the compressor hose bolt from the compressor.
16. Remove the compressor hose from the compressor.
17. Remove and discard the O-rings from the compressor. Refer to O-Ring Replacement .
18. Install a protective cap to the compressor to prevent contamination and desiccant saturation.
19. Remove the compressor hose from the vehicle.
20. Remove and discard the sealing washers from the TXV and the condenser ends of the compressor hose. Refer to Sealing Washer Replacement .

1. Install new seal washers to the TXV and the condenser ends of the compressor hose. Refer to Sealing Washer Replacement .
2. Position the compressor hose in the vehicle.
3. Remove the protective cap from the compressor.
4. Install new O-rings to the compressor. Refer to O-Ring Replacement .
5. Install the compressor hose to the compressor.

Notice: 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.

6. Install the compressor hose bolt to the compressor.

Tighten
Tighten the bolt to 27 N·m (20 lb ft).

7. Lower vehicle.



8. On L81 vehicles, remove the protective cap from the suction hose jumper.
9. Connect the compressor hose to the suction hose jumper.
10. Install the compressor hose nut to the suction hose jumper.

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




11. Remove the protective cap from the TXV.
12. Install the compressor hose to the TXV.
13. Install the compressor hose nut to the TXV.

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




14. Remove the protective cap from the condenser.
15. Install the compressor hose to the condenser.
16. Install the compressor hose nut to the condenser.

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




17. Install the compressor hose to the battery box.
18. Install the compressor hose nut to the battery box.

Tighten
Tighten the nut to 8 N·m (71 lb in).

19. Install left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement in Lighting Systems.
20. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging .
21. Test the affected A/C joints for leaks using J 39400-A .