Air Conditioning Compressor Replacement

Compressor Replacement (2.2L (L61), 2.4L (LE5))

Tools Required

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

Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Raise and support the vehicle. Refer to Vehicle Lifting.
3. Remove the right side engine splash shield.




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 CVC 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 Compressor Oil Balancing.






Notice: Refer to Fastener Notice.

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

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




3. Install new sealing washers on the hose fittings.
4. Install the hose assembly to the compressor.
5. Install the assembly bolt.

Tighten the bolt to 20 N.m (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.
10. Lower the vehicle.
11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
12. Leak test the fittings using J 39400-A.