HHR 2006-2008

Removal & Installation

Print

2.0L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge the refrigerant. Refer to Heating & Air Conditioning, discharging the system.
  4.  
  5. Raise and safely support the vehicle.

    Click image to see an enlarged view

    Fig. Remove the right front fender liner

  6.  
  7. Remove the right side tire and wheel assembly.
  8.  
  9. Remove the 7 front right side wheelhouse liner screws (1).
  10.  
  11. Remove the 10 right front wheelhouse liner retainers (2) using a flat-bladed tool.
  12.  
  13. Remove or disconnect the following:

    The accessory drive belt. Refer to Accessory Drive Belts, removal and installation
     
    The electrical connector from the compressor

    Click image to see an enlarged view

    Fig. Remove the compressor and condenser hose assembly bolt from the compressor

     
    The compressor and condenser hose assembly bolt from the compressor
     
    The compressor and condenser hose assembly from the compressor
     
    Remove and discard the sealing washers

    Click image to see an enlarged view

    Fig. Remove the auxiliary intercooler pump bolts and position the pump toward the driver-s side of the vehicle

     
    The auxiliary intercooler pump bolts and position the pump toward the driver-s side of the vehicle
     
    The compressor mounting bolts
     
    The compressor

    Click image to see an enlarged view

    Fig. Remove the compressor mounting bolts and the A/C compressor

     

  14.  

To install:


WARNING
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, use the following procedure:
    1. Drain and measure as much of the refrigerant oil as possible from the removed compressor.
    2.  
    3. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.

      Click image to see an enlarged view

      Fig. Drain the oil from both the suction and discharge ports of the removed compressor

    4.  
    5. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
    6.  
    7. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
    8.  
    9. Properly discard the used refrigerant oil.
      WARNING
      The refrigerant oil in the A/C system must be balanced during compressor replacement.


      NOTE
      The replacement compressor is shipped with 2.5 oz (74 ml) of refrigerant oil.



      Click image to see an enlarged view

      Fig. Balancing the refrigerant oil in the A/C system by adding PAG oil to the A/C compressor

    10.  
    11. Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor. If the amount of refrigerant oil drained and recorded from the removed compressor is:

      Less than 2.5 oz (74 ml), leave the 2.5 oz (74 ml) in the replacement compressor
       
      More than 2.5 oz (74 ml), add to the compressor the difference between the 2.5 oz (74 ml) and the amount drained
       

    12.  

  2.  
  3. Install or connect the following:

    The compressor and the bolts to the engine. Tighten the bolts to 18 ft. lbs. (25 Nm)
     
    New sealing washers on the hose fittings
     
    The hose assembly to the compressor
     
    The assembly bolt. Tighten the bolt to 15 ft. lbs. (20 Nm)
     
    The compressor electrical connector
     
    The auxiliary intercooler pump. Tighten the pump bolt to 88 inch lbs. (10 Nm)
     
    The accessory drive belt. Refer to Accessory Drive Belts, removal and installation
     
    The front fender liner with the 7 liner screws tightened to 18 inch lbs. (2 Nm) and the 10 liner retainers placed into position
     

  4.  
  5. Lower the vehicle.
  6.  
  7. Evacuate and charge the refrigerant system. Refer to Heating & Air Conditioning, evacuating the system and charging the system.
  8.  
  9. Leak test the fittings. Refer to Heating & Air Conditioning, leak testing.
  10.  

2.2L & 2.4L Engines-First Design



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge the refrigerant. Refer to Heating & Air Conditioning, discharging the system.
  4.  
  5. Raise and safely support the vehicle.

    Click image to see an enlarged view

    Fig. Remove the right front fender liner

  6.  
  7. Remove the right side tire and wheel assembly.
  8.  
  9. Remove the 7 front right side wheelhouse liner screws (1).
  10.  
  11. Remove the 10 right front wheelhouse liner retainers (2) using a flat-bladed tool.
  12.  
  13. Remove or disconnect the following:

    The accessory drive belt. Refer to Accessory Drive Belts, removal and installation
     
    The electrical connector from the compressor

    Click image to see an enlarged view

    Fig. Remove the compressor and condenser hose assembly bolt from the compressor

     
    The compressor and condenser hose assembly bolt from the compressor
     
    The compressor and condenser hose assembly from the compressor
     
    Remove and discard the sealing washers
     
    The compressor mounting bolts
     
    The compressor

    Click image to see an enlarged view

    Fig. Remove the compressor mounting bolts and the A/C compressor

     

  14.  

To install:


WARNING
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, use the following procedure:
    1. Drain and measure as much of the refrigerant oil as possible from the removed compressor.
    2.  
    3. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.

      Click image to see an enlarged view

      Fig. Drain the oil from both the suction and discharge ports of the removed compressor

    4.  
    5. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
    6.  
    7. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
    8.  
    9. Properly discard the used refrigerant oil.
      WARNING
      The refrigerant oil in the A/C system must be balanced during compressor replacement.


      NOTE
      The replacement compressor is shipped with 2.5 oz (74 ml) of refrigerant oil.



      Click image to see an enlarged view

      Fig. Balancing the refrigerant oil in the A/C system by adding PAG oil to the A/C compressor

    10.  
    11. Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor. If the amount of refrigerant oil drained and recorded from the removed compressor is:

      Less than 2.5 oz (74 ml), leave the 2.5 oz (74 ml) in the replacement compressor
       
      More than 2.5 oz (74 ml), add to the compressor the difference between the 2.5 oz (74 ml) and the amount drained
       

    12.  

  2.  
  3. Install or connect the following:

    The compressor and the bolts to the engine. Tighten the bolts to 18 ft. lbs. (25 Nm)
     
    New sealing washers on the hose fittings
     
    The hose assembly to the compressor
     
    The assembly bolt. Tighten the bolt to 15 ft. lbs. (20 Nm)
     
    The compressor electrical connector
     
    The accessory drive belt. Refer to Accessory Drive Belts, removal and installation
     
    The front fender liner with the 7 liner screws tightened to 18 inch lbs. (2 Nm) and the 10 liner retainers placed into position
     

  4.  
  5. Lower the vehicle.
  6.  
  7. Evacuate and charge the refrigerant system. Refer to Heating & Air Conditioning, evacuating the system and charging the system.
  8.  
  9. Leak test the fittings. Refer to Heating & Air Conditioning, leak testing.
  10.  

2.2L & 2.4L Engines-Second Design



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge the refrigerant. Refer to Heating & Air Conditioning, discharging the system.
  4.  
  5. Raise and safely support the vehicle.

    Click image to see an enlarged view

    Fig. Remove the right side engine splash shield: the splash shield push-in retainers (1) and the splash shield (2)

  6.  
  7. Remove the right side engine splash shield:
    1. Remove the right side tire and wheel assembly.
    2.  
    3. Remove all splash shield push-in retainers (1) except the one hidden by the inner fender.
    4.  
    5. Remove the front 3 inner fasteners and reposition to access the hidden fastener for removal.
    6.  

  8.  
  9. Remove or disconnect the following:

    The accessory drive belt. Refer to Accessory Drive Belts, removal and installation
     
    The electrical connector from the compressor

    Click image to see an enlarged view

    Fig. Remove the compressor and condenser hose assembly bolt from the compressor

     
    The compressor and condenser hose assembly bolt from the compressor
     
    The compressor and condenser hose assembly from the compressor
     
    Remove and discard the sealing washers
     
    The compressor mounting bolts
     
    The compressor

    Click image to see an enlarged view

    Fig. Remove the compressor mounting bolts and the A/C compressor

     

  10.  

To install:


WARNING
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.


WARNING
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, use the following procedure:
    1. Drain and measure as much of the refrigerant oil as possible from the removed compressor.
    2.  
    3. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.

      Click image to see an enlarged view

      Fig. Drain the oil from both the suction and discharge ports of the removed compressor

    4.  
    5. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
    6.  
    7. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
    8.  
    9. Properly discard the used refrigerant oil.
      WARNING
      The refrigerant oil in the A/C system must be balanced during compressor replacement.


      NOTE
      The replacement compressor is shipped with 2.5 oz (74 ml) of refrigerant oil.



      Click image to see an enlarged view

      Fig. Balancing the refrigerant oil in the A/C system by adding PAG oil to the A/C compressor

    10.  
    11. Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor. If the amount of refrigerant oil drained and recorded from the removed compressor is:

      Less than 2.5 oz (74 ml), leave the 2.5 oz (74 ml) in the replacement compressor
       
      More than 2.5 oz (74 ml), add to the compressor the difference between the 2.5 oz (74 ml) and the amount drained
       

    12.  

  2.  
  3. Install or connect the following:

    The compressor and the bolts to the engine. Tighten the bolts to 16 ft. lbs. (22 Nm)
     
    New sealing washers on the hose fittings
     
    The hose assembly to the compressor
     
    The assembly bolt. Tighten the bolt to 15 ft. lbs. (20 Nm)
     
    The compressor electrical connector
     
    The accessory drive belt. Refer to Accessory Drive Belts, removal and installation
     

  4.  
  5. Install the right side engine splash shield:
    1. Install the hidden fastener and then install the 3 inner fasteners.
    2.  
    3. Install all splash shield push-in retainers.
    4.  
    5. Install the right side tire and wheel assembly. Tighten lug nuts to 100 ft. lbs (140 Nm).
    6.  

  6.  
  7. Lower the vehicle.
  8.  
  9. Evacuate and charge the refrigerant system. Refer to Heating & Air Conditioning, evacuating the system and charging the system.
  10.  
  11. Leak test the fittings. Refer to Heating & Air Conditioning, leak testing.
  12.  

 
label.common.footer.alt.autozoneLogo