Chevrolet Sonic Repair Manual: Air Conditioning Compressor and Condenser Hose Replacement (LUV)

Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the drivetrain and front suspension frame skid plate if equipped. Refer to Drivetrain and Front Suspension Frame Skid Plate Replacement.
3. Remove the front fascia assembly. Refer to Front Bumper Fascia Replacement.
4. Disconnect the A/C refrigerant pressure sensor electrical connector.


5. Remove air conditioning compressor and condenser hose nut (1).
6. Remove air conditioning compressor and condenser hose (2) from A/C condenser.


7. Remove A/C compressor and condenser hose bolts (1).
8. Remove A/C compressor and condenser hose (2) from A/C compressor.
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9. Remove air conditioning compressor and condenser hose nut (1).
10. Remove air conditioning compressor and condenser hose (2) from refrigerant hose.
11. Remove air conditioning compressor and condenser hose from the vehicle.
12. Discard all the old air conditioning seals.
13. Transfer the air conditioning pressure sensor to the new line assembly.

Installation Procedure

1. Install NEW air conditioning system seals. Refer to Air Conditioning System Seal Replacement.
2. Install air conditioning compressor and condenser hose assembly into the vehicle.
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Caution:

Refer to Fastener Caution.

3. Install air conditioning compressor and condenser hose (2) to the refrigerant hose.
4. Install air conditioning compressor and condenser hose nut (1) and tighten the nut to  22 Y (16 lb ft)

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5. Install air conditioning compressor and condenser hose (2) to the A/C compressor.
6. Install air conditioning compressor and condenser hose bolts (1) and tighten the bolt to  22 Y (16 lb ft)

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7. Install air conditioning compressor and condenser hose (2) to the A/C condenser.
8. Install air conditioning compressor and condenser hose nut (1) and tighten the nut to  22 Y (16 lb ft)

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9. Connect the A/C refrigerant pressure sensor electrical connector.
10. Install the front fascia assembly. Refer to Front Bumper Fascia Replacement.
11. Install the drivetrain and front suspension frame skid plate if equipped. Refer to Drivetrain and Front Suspension Frame Skid Plate Replacement.
12. Charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.