Cavalier, Sunfire 2001-2005

Removal & Installation

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2.2L (VIN 4) Engine




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Recover the A/C system.
  2.  
  3. Remove the drive belt.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the right front fender liner.
  8.  
  9. Disconnect the compressor clutch electrical connector.
  10.  
  11. Remove the compressor hose assembly from the compressor.
  12.  
  13. Remove the compressor bolts and.
  14.  
  15. Remove the compressor.
  16.  

To install:


NOTE
NEW A/C compressors are shipped WITHOUT poly-alkylene glycol (PAG) oil. Only use the approved Pag Oil, failure to do so will result in system failure.

  1. If a NEW A/C compressor is being installed, add 60 ml (2 oz), of PAG Oil to the compressor. If reinstalling the OLD A/C compressor perform the following:
    NOTE
    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.



    Drain, measure and record the amount of PAG oil from both the suction and discharge ports and the crankcase in the A/C compressor.
     
    If the measured amount of PAG oil drained is less than or equal to 60 ml (2 oz), add 60 ml (2 oz) of new, clean PAG oil to the A/C compressor.
     
    If the measured amount of PAG oil drained is greater than 60 ml (2 oz), add the same amount of new clean PAG oil to the A/C compressor.
     

  2.  
  3. Install the compressor crankcase oil drain bolt and tighten the compressor crankcase oil drain bolt to  15 ft. lbs. (20 Nm)
  4.  
  5. Install the compressor to the compressor mounting bracket.
  6.  
  7. Install the compressor mounting bolts and tighten the front compressor mounting bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. Tighten the rear compressor mounting bolt to 45 ft. lbs. (65 Nm).
  10.  
  11. Install the compressor hose assembly to the compressor.
  12.  
  13. Connect the clutch electrical connector.
  14.  
  15. Install the right front fender liner.
  16.  
  17. Lower the vehicle.
  18.  
  19. Install the drive belt.
  20.  
  21. Evacuate and recharge the A/C system.
  22.  
  23. Leak test the fittings of the component using the special tool J39400-A.
  24.  

2.2L (VIN F) Engine




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Recover the refrigerant.
  2.  
  3. Remove the drive belt.
  4.  
  5. Disconnect the electrical connector from the compressor.
  6.  
  7. Remove the bolt holding the compressor hose assembly to the compressor.

    Click image to see an enlarged view

    Fig. Remove the hose assembly from the compressor

  8.  
  9. Remove the hose assembly from the compressor.
  10.  
  11. Remove and discard the sealing washers.
  12.  
  13. Remove the compressor mounting bolts.
  14.  
  15. Remove the compressor.
  16.  
  17. If replacing the compressor, drain and measure as much of the oil from the compressor as possible using the following procedure:
  18.  
  19. Drain the oil from both the suction and the discharge ports into a clean container.
  20.  
  21. Remove the compressor crankcase oil drain plug and drain the crankcase oil into the same container.
  22.  
  23. Measure and record the amount of oil drained from the compressor. This measurement will be used during the compressor installation procedure.
  24.  
  25. Properly discard the used PAG oil.
  26.  

To install:


NOTE
Do not mix refrigerant oils. Use of incorrect refrigerant oil will cause compressor failure. The CVC compressor uses a low viscosity refrigerant oil, GM P/N 12378526 (Canadian P/N 88900060).


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

  1. Drain the PAG oil from the new compressor into the clean calibrated measuring container. Drain from the crankcase and from the rear head ports. If the amount of old oil drained is less than or equal to 75 ml (2.5 oz), add 75 ml of new oil into the new compressor through the crankcase bolt hole. If the amount of old oil drained is greater than 75 ml (2.5 oz), add the equivalent amount of new oil into the new compressor through the crankcase bolt hole.
    NOTE
    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.  
  3. Install the crankcase oil drain bolt to the compressor and tighten the drain bolt to 12 ft. lbs. (16 Nm).
  4.  
  5. Rotate the clutch driver 3 times to lubricate the internal swashplate and the piston shoes.
  6.  
  7. Install the bolts and the compressor to the engine and tighten the bolts to 16 ft. lbs. (22 Nm).
  8.  
  9. Install NEW sealing washers on the compressor ports.
  10.  
  11. Install the compressor hose assembly .
  12.  
  13. Install the compressor hose assembly nut and tighten the nut to 12 ft. lbs. (16 Nm).
  14.  
  15. Connect the compressor electrical connector.
  16.  
  17. Install the drive belt.
  18.  
  19. Lower the vehicle.
  20.  
  21. Evacuate and charge the refrigerant system.
  22.  

2.4L Engines




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Recover the refrigerant.
  2.  
  3. Remove the drive belt.
  4.  
  5. Remove the right front fender liner.
  6.  
  7. Disconnect the clutch electrical connector from the compressor.
  8.  
  9. Remove the EVAP canister purge solenoid valve from the compressor mounting stud.
  10.  
  11. Remove the bolt holding the compressor hose assembly to the compressor.
  12.  
  13. Remove the compressor hose assembly from the compressor.
  14.  
  15. Remove and discard the sealing washers.

    Click image to see an enlarged view

    Fig. Remove two bolts (5) holding the compressor to the oil pan and the upper two mounting bolts (2,3)

  16.  
  17. Remove 2 bolts holding the compressor to the oil pan.
  18.  
  19. Remove the upper 2 mounting bolts.
  20.  
  21. Remove the compressor.
  22.  
  23. If replacing the same compressor, drain and measure as much of the oil from the compressor as possible using the following procedure:
  24.  
  25. Drain the oil from both the suction and the discharge ports into a clean container.
  26.  
  27. Remove the compressor crankcase oil drain plug and drain the crankcase oil into the same container.
  28.  
  29. Measure and record the amount of oil drained from the compressor. This measurement will be used during the compressor installation procedure. Properly discard the used PAG oil.
  30.  

To install:


NOTE
NEW A/C compressors are shipped WITHOUT poly-alkylene glycol (PAG) oil. Use of the incorrect PAG oil can result in compressor failure.

  1. If a NEW A/C compressor is being installed, add 60 ml (2 oz) of PAG Oil to the compressor.
    NOTE
    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.  
  3. Install the crankcase oil drain bolt to the replacement compressor and tighten the drain bolt to 15 ft. lbs. (20 Nm).

    Click image to see an enlarged view

    Fig. Install the compressor (4) and loosely install the upper 2 compressor mounting bolts (2,3) and loosely install the 2 oil pan to compressor bolts (5)

  4.  
  5. Install the compressor  and loosely install the upper 2 compressor mounting bolts.
  6.  
  7. Loosely install the 2 oil pan to compressor bolts and tighten the mounting bolts to 37 ft. lbs. (50 Nm).
  8.  
  9. Tighten the oil pan bolts to 37 ft. lbs. (50 Nm).
  10.  
  11. Connect the clutch electrical connector.
  12.  
  13. Install NEW sealing washers to the compressor ports.
  14.  
  15. Install the compressor hose assembly to the compressor.
  16.  
  17. Install the bolt holding the compressor hose assembly to the compressor and tighten the bolt to 24 ft. lbs. (33 Nm).
  18.  
  19. Install the EVAP canister purge solenoid valve to the compressor mounting stud.
  20.  
  21. Install the right front fender liner.
  22.  
  23. Install the drive belt.
  24.  
  25. Evacuate and recharge the A/C system.
  26.  
  27. Leak test the fittings of the component using special tool J39400-A.
  28.  

 
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