Compressor Replacement

COMPRESSOR REPLACEMENT

TOOLS REQUIRED
J 39400-A Halogen Leak Detector

REMOVAL

IMPORTANT: Performing this procedure will require replacement of the forward engine frame bolts.




1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the air cleaner assembly.
3. Remove the accessory drive belt.
4. Raise and support the vehicle. Refer to Vehicle Lifting.
5. Disconnect the electrical connector from the compressor.




6. Remove the compressor hose bolt from the compressor.
7. Remove the compressor hose from the compressor.
8. Remove and discard the O-rings from the compressor.
9. Install a cap to the compressor hose to prevent moisture or contamination from entering the A/C system.




10. Place an adjustable jack stand or a lifting device under the front edge of the engine frame.
11. Loosen, but do not remove, the front engine frame mounting bolts.
12. Lower the forward edge of the engine frame approximately 12.7 mm (0.5 in).
13. Remove the compressor bolts from the engine.
14. Remove the compressor from the vehicle.

INSTALLATION
1. If replacing the compressor, refer to Compressor Oil Balancing.

NOTE: 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.




2. Install the compressor to the vehicle.
3. Install the compressor bolts to the engine.

Tighten the bolts to 22 N.m (16 lb ft).

NOTE: Refer to Fastener Notice in Service Precautions.

4. Raise the forward edge of the engine frame.
5. Remove and discard the right hand front engine frame bolt.
6. Install a new right hand front engine frame bolt.
7. Remove and discard the left hand front engine frame bolt.
8. Install a new left hand front engine frame bolt.
9. Tighten the engine frame bolts to the body.

Tighten the bolts to 155 N.m (114 lb ft).

10. Remove the adjustable jack stand or lifting device from the front edge of the engine frame.




11. Remove the caps from the compressor and the compressor hose.
12. Install new O-rings to the compressor.
13. Install the compressor hose to the compressor.
14. Install the compressor hose bolt to the compressor.

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




15. Connect the electrical connector to the compressor.
16. Lower the vehicle. Refer to Vehicle Lifting.
17. Install the accessory drive belt.
18. Install the air cleaner assembly.
19. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging.
20. Test the affected A/C joints for leaks using J 39400-A.