GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Malibu 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 O-Ring Replacement

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

    Object Number: 297225 Size: SH
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. For compression-style fittings use a back-up wrench on the A/C refrigerant component (smaller size) fitting (2), then loosen the A/C refrigerant hose (larger size) fitting (1).
  3. For banjo-style fittings remove the bolt or the nut retaining the A/C refrigerant hose to the A/C refrigerant component.

    4. Important: Cap or tape the open A/C refrigerant hose and the A/C refrigerant component immediately.

  4. Disconnect the A/C refrigerant hose from the A/C refrigerant component, discard the O-ring seal and cap or tape the A/C refrigerant hose and the A/C refrigerant component to prevent contamination.

Installation Procedure

    Object Number: 297232 Size: SH
  1. Remove the cap or tape from the A/C refrigerant hose and the A/C refrigerant component.
  2. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant hose and the A/C refrigerant component.
  3. Lightly coat the new O-ring seal (1) with mineral base 525 viscosity refrigerant oil.

    4. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system.

  4. For compression-style fittings carefully slide the new O-ring seal (1) onto the A/C refrigerant hose until seated.

    5. Object Number: 297228 Size: SH
  5. For banjo-style fittings carefully slide the new O-ring seal (1) onto the A/C refrigerant hose until seated.

    6. Leave a light coating of the refrigerant oil on the A/C refrigerant hose in the area indicated (2) ONLY.


    Object Number: 297225 Size: SH
  6. Install the A/C refrigerant hose to the A/C refrigerant component.
  7. For compression-style fittings use a back-up wrench on the A/C refrigerant component (smaller size) fitting (2), then tighten the A/C refrigerant hose (larger size) fitting (1) to specification.
  8. For banjo-style fittings install the bolt or the nut retaining the A/C refrigerant hose to the A/C refrigerant component, then tighten to specification.
  9. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  10. Leak test the fittings of the component using the J 39400-A .