For 1990-2009 cars

# A/C HOSE AND CLAMP HOSE LEAK REPAIR

WHEN A FREON LEAK IS DETECTED AT AN AIR CONDITIONING REFRIGERANT HOSE CONNECTION WHICH HAS A CRIMPED METAL BAND, THE CRIMPED BAND MAY BE REPLACED WITH A SPECIAL SCREW-TYPE SERVICE CLAMP ACCORDING TO THE FOLLOWING CLAMP REPLACEMENT PROCEDURE. ALSO INCLUDED IS A HOSE REPAIR PROCEDURE FOR A DAMAGED AND/OR LEAKING REFRIGERANT HOSE. THIS ALLOWS THE DEALER THE ADDED FLEXIBILITY OF REPAIRING HOSE ASSEMBLIES RATHER THAN REPLACING THEM.

WARRANTY REPAIRS SHOULD CONTINUE THE REPLACEMENT PROCEDURE

#### NOTE: HOSES MARKED WITH THE WORDS "PARKER", PARKER PARFLEX 80" OR "PARFLEX 80" ARE NYLON AND CANNOT BE REPAIRED BY THESE PROCEDURES. THESE HOSES SHOULD BE REPLACED AS ENTIRE ASSEMBLIES. CLAMP REPLACEMENT 1. COMPLETELY DISCHARGE THE AIR CONDITIONING SYSTEM BY AN APPROVED METHOD. 2. DISCONNECT THE ENTIRE HOSE ASSEMBLY AND REMOVE IT FROM THE VEHICLE. PUT TAPE OR APPROVED PLASTIC CAPS OVER ALL OF THE OPENINGS TO THE SYSTEM, INCLUDING THE REMOVED HOSE ASSEMBLY, TO PREVENT DIRT AND MOISTURE CONTAMINATION. 3. USING A FINE TOOTHED HACKSAW, CUT A WIDE NOTCH ALL THE WAY ACROSS THE CRIMPED METAL BAND. SEE FIGURE 1. NOTICE: AVOID CUTTING THE HOSE MATERIAL 4. USING A COLD CHISEL AND A SMALL HAMMER, TAP CAREFULLY AT THE NOTCH UNTIL THE BAND IS SPLIT ALL THE WAY ACROSS. SEE FIGURE 2. 5. PRY THE BAND UNTIL IT CAN BE REMOVED WITHOUT CUTTING THE HOSE MATERIAL WITH THE BURRED EDGES. NOTICE: IF THE HOSE MATERIAL HAS BEEN CUT, ALL OR PART OF THE HOSE MUST BE REPLACED. SEE TABLE "A" FOR APPLICABLE CLAMPS, HOSE MATERIAL, AND SPLICER FITTING KITS. THE REPAIRED HOSE SHOULD BE THE SAME OVERALL LENGTH AS THE FITTING KITS. THE REPAIRED HOSE SHOULD BE THE SAME OVERALL LENGTH AS THE ORIGINAL. 6. INSTALL THE SPECIAL SCREW-TYPE SERVICE CLAMP SO THAT THE LOCATOR LUG IS POSITIONED ON THE HOSE END. SEE FIGURE 3. TIGHTEN CLAMP TO 4.5 N.M (40 IN. LBS.) 7. REINSTALL THE HOSE ASSEMBLY ON THE VEHICLE WITH NEW O-RINGS WHERE USED. A/C COMPRESSOR OIL SHOULD BE USED TO LUBRICATE THE O-RINGS. 8. PARTIALLY CHARGE THE SYSTEM AND PERFORM A LEAK TEST BEFORE COMPLETELY RECHARGING. HOSE REPAIR 1. PERFORM STEPS #1 OF THE CLAMP REPLACEMENT PROCEDURE. 2. USING A FINE TOOTH HACKSAW, CUT ALL THE WAY THROUGH THE METAL BAND CLAMP AND INTO THE TOP LAYER OF THE HOSE ON ONE END OF THE HOSE IF ONLY PART OF IT IS BEING REPLACED OR ON BOTH ENDS IF THE ENTIRE HOSE IS BEING REPLACED. 3. PRY THE BAND OPEN UNTIL IT CAN BE REMOVED WITHOUT DAMAGING THE FITTING. 4. IF ONLY PART OF THE HOSE IS BEING REPLACED; A. CUT THE BAD PART AWAY SQUARELY. B. USE A NEW SECTION OF HOSE OF THE SAME INSIDE DIAMETER AND CUT IT 13MM (1/2") SHORTER THAN THE REMOVED SECTION. SEE TABLE "A" FOR PARTS APPLICATIONS. C. INSTALL THE PROPER SIZE SPLICER FITTING KIT PER THE INSTRUCTIONS BETWEEN THE REMAINING SECTION AND NEW SECTION OF HOSE AND INSTALL THE OTHER END OF THE HOSE ON THE FITTING. ALIGN FITTINGS SO THAT THERE WILL BE NO TWIST IN THE HOSE WHEN IT IS ON THE VEHICLE. SEE FIGURE 4. SEE TABLE "A" FOR PARTS APPLICATIONS. D. INSTALL TWO SERVICE CLAMPS AT A SPLICE AND ONE AT A FITTING AS IN STEP #6 OF THE CLAMP REPLACEMENT PROCEDURE. E. PERFORM STEPS #7 AND #8 OF THE CLAMP REPLACEMENT PROCEDURE. 5. IF THE ENTIRE SECTION OF HOSE IS BEING REPLACED; A. CUT THE OLD HOSE OFF OF BOTH FITTINGS. B. INSTALL A NEW SECTION OF HOSE OF THE SAME INSIDE DIAMETER AND CUT TO THE SAME LENGTH AND INSTALL IT ON THE FITTINGS. ALIGN FITTINGS SO THAT THERE WILL BE NO TWIST IN THE HOSE WHEN IT IS ON THE VEHICLE. SEE TABLE A FOR PARTS APPLICATIONS. C. INSTALL A SERVICE CLAMP AT EACH END AS IN STEP #6 OF THE CLAMP REPLACEMENT PROCEDURE. D. PERFORM STEPS #7 AND #8 OF THE CLAMP REPLACEMENT PROCEDURE. TABLE A AIR CONDITIONING SERVICE CLAMPS, HOSE MATERIAL AND SPLICER FITTING KITS GROUP # PART # DESCRIPTION HOSE I.D. ROLL LENGTH 9.242/ 1.166 3909030 A/C HOSE CLAMP (HOSE O.D. 11/16"-1-7/32") 8.962 230882 A/C REFRIGERANT HOSE 5/16" 15' 8.962 230883* A/C REFRIGERANT HOSE 13/32" 15' 8.962 12309273* A/C REFRIGERANT HOSE 13/32" 15' 8.962 12309274 A/C REFRIGERANT HOSE 13/32" 50' 8.962 230884* A/C REFRIGERANT HOSE 1/2" 15' 8.962 12309271* A/C REFRIGERANT HOSE 1/2" 15' 8.962 12309272 A/C REFRIGERANT HOSE 1/2" 50' 8.962 12309275 A/C REFRIGERANT HOSE 5/8" 15' 8.962 12309276 A/C REFRIGERANT HOSE 5/8" 50' 9.222 3023686 SPLICER FITTING KIT 5/16" 9.222 3023687 SPLICER FITTING KIT 13/32" 9.222 3023688 SPLICER FITTING KIT 1/2" 9.222 3023689 SPLICER FITTING KIT 5/8" *HOSES IN THIS LIST WHICH ARE OF THE SAME INSIDE DIAMETER AND ROLL LENGTH ARE INTERCHANGEABLE. DIFFERENT PART NUMBERS DENOTE DIFFERNT MANUFACTURER SOURCES IN THESE CASES.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.