ION 2006-2007

Removal & Installation

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WARNING
Before beginning this procedure, refer to the precautions at the beginning of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Recover the refrigerant.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the right front fender liner.
  6.  
  7. Remove the drive belt.
  8.  
  9. Disconnect the electrical connector from the compressor.
  10.  
  11. Remove the compressor and condenser hose assembly bolt from the compressor.
  12.  
  13. Remove the compressor and condenser hose assembly from the compressor.
  14.  
  15. Remove and discard the sealing washers.
  16.  
  17. Remove the auxiliary intercooler pump bolts and position the pump toward the driver side of the vehicle.
  18.  
  19. Remove the compressor mounting bolts.
  20.  
  21. Remove the compressor.
  22.  

To install:


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.


NOTE
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. Install the compressor and the bolts to the engine, and tighten the bolts to 16 ft. lbs. (22 Nm).
  2.  
  3. Install new sealing washers on the hose fittings.
  4.  
  5. Install the hose assembly to the compressor.
  6.  
  7. Install the assembly bolt, and tighten the bolt to 15 ft. lbs. (20 Nm).
  8.  
  9. Connect the compressor electrical connector.
  10.  
  11. Install the auxiliary intercooler pump, and tighten the pump bolt to 88 inch lbs. (10 Nm).
  12.  
  13. Use special tool J44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
  14.  
  15. Install the drive belt.
  16.  
  17. Install the front fender liner.
  18.  
  19. Lower the vehicle.
  20.  
  21. Evacuate and charge the refrigerant system.
  22.  
  23. Leak test the fittings using special tool J39400-A.
  24.  

 
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