Second Design

Air Conditioning Compressor Replacement (RPOs L61, LE5 - Second Design)

Special Tools

- J 39400-A Halogen Leak Detector
- J 44811 Accessory Belt Tensioner Unloader

Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Service and Repair.
2. Raise and support the vehicle.
3. Remove the right side engine splash shield. Refer to Engine Splash Shield Replacement - Right Side Service and Repair.






4. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
5. Remove the drive belt.






6. Disconnect the electrical connector from the compressor.






7. Remove the compressor and condenser hose assembly bolt from the compressor.
8. Remove the compressor and condenser hose assembly from the compressor.
9. Remove and discard the sealing washers.






10. Remove the compressor mounting bolts.
11. Remove the compressor.

Installation Procedure

Notice: Do NOT mix refrigerant oils. Use of incorrect refrigerant oil will cause compressor failure. This compressor uses a low viscosity refrigerant oil, Saturn P/N 22695048.

Important: NEW compressor assemblies are shipped with a partial poly-alkylene glycol (PAG) refrigerant oil charge. Use of the incorrect PAG oil can result in compressor failure.

1. If you are replacing the compressor, refer to Air Conditioning Compressor Oil Balancing.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.






2. Install the compressor and the bolts to the engine.

Tighten
Tighten the bolts to 22 Nm (16 lb ft).






3. Install new sealing washers on the hose fittings. Refer to Sealing Washer Replacement Service and Repair.
4. Install the hose assembly to the compressor.
5. Install the assembly bolt.

Tighten
Tighten the bolt to 20 Nm (15 lb ft).






6. Connect the compressor electrical connector.






7. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
8. Install the drive belt.
9. Install the right side engine splash shield. Refer to Engine Splash Shield Replacement - Right Side Service and Repair.
10. Lower the vehicle.
11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging Service and Repair.
12. Leak test the fittings using J 39400-A.