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HOMESERVICE MANUALSCHEVROLET2003S10 PICKUP 2D PICKUP, 2.2 H, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 240 (HEATING, VENTILATION AND AIR CONDITIONING)REPAIR INSTRUCTIONSCOMPRESSOR HOSE ASSEMBLY REPLACEMENT (L61)INSTALLATION PROCEDURE
2003 Chevrolet S10 Pickup 2D Pickup, 2.2 H, Automatic

Installation Procedure

2003 Chevrolet S10 Pickup 2D Pickup, 2.2 H, AutomaticSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Compressor Hose, Bolt, Compressor, O-Rings & Protective Cap
    GM933655Courtesy of GENERAL MOTORS CORP.
  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.
    6. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  6. Install the compressor hose bolt to the compressor.

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

  7. Lower vehicle.
    8. Fig 2: Installing Compressor Hose To Evaporator Hose
    GM933725Courtesy of GENERAL MOTORS CORP.
  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. Fig 3: Compressor Hose, Nut & TXV
    GM931940Courtesy of GENERAL MOTORS CORP.
  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. Fig 4: Compressor Hose, Nut, Condenser & Protective Cap
    GM932379Courtesy of GENERAL MOTORS CORP.
  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. Fig 5: Compressor Hose, Nut & Battery Box
    GM932512Courtesy of GENERAL MOTORS CORP.
  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  . See Special Tools .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.