Chevrolet Sonic Repair Manual: Air Conditioning System Seal Replacement

Removal Procedure

1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure.

Note:

Cap or tape the open A/C refrigerant components immediately to prevent system contamination.

2. Cap or tape the A/C refrigerant components.


3. Remove the sealing washer (1) from the A/C refrigerant component.
4. Inspect the seal washer for signs of damage to help determine the root cause of the failure.
5. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.

Note:

DO NOT reuse sealing washer.

6. DISCARD the sealing washer.

Installation Procedure

Note:

Flat washer type seals do not require lubrication.

1. Inspect the new sealing washer for any signs of cracks, cuts, or damage.

   Do not use a damaged sealing washer.

2. Remove the cap or tape from the A/C refrigerant components.


3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
4. Carefully install the NEW sealing washer (1) onto the A/C refrigerant component.

   The sealing washer (1) must completely bottom against the surface of the fitting.

Note:

After tightening the A/C components, there should be a slight sealing gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component.

5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.