ION, L-Series, S-Series 1999-2005

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.


NOTE
When servicing the compressor, keep dirt and foreign material from getting on or into the compressor parts and system. Clean tools and clean work area are important for proper service. The compressor connections and the outside of the compressor should be cleaned before any ON CAR repairs, or before removal of the compressor. The parts must be kept clean at all times and any parts to be assembled should be cleaned with a non-petroleum based solvent and dried with air. Use only lint free cloths to wipe parts.

  1. Do not allow solvent to enter compressor or hoses.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Recover the refrigerant using an approved refrigerant recovery system. Measure the amount of oil lost during recovery and record.
    NOTE
    Verifying the purity of the refrigerant with a refrigerant purity identifier before recovery is recommended.

  6.  
  7. Remove the nuts from the combination valve studs.
  8.  
  9. Remove the air hose.
  10.  
  11. Remove the vacuum source hose. There is no need to disconnect the internal vacuum hose for this procedure.

    Click image to see an enlarged view

    Fig. Remove the combination valve and gasket from the rear air compressor bracket

  12.  
  13. Remove the combination valve and gasket from the rear air compressor bracket.
  14.  
  15. Position the combination valve and gasket away from the A/C compressor bracket.
  16.  
  17. Remove the air pipe nuts from the exhaust manifold studs.
  18.  
  19. Remove the air pipe.
  20.  
  21. Remove the accessory drive belt from the compressor clutch pulley by rotating the belt tensioner clockwise using a 14 mm wrench or equivalent can be used.

    Click image to see an enlarged view

    Fig. Disconnect the compressor clutch electrical connector

  22.  
  23. Disconnect the compressor clutch electrical connector.
    CAUTION
    Do not remove hoses or lines before system is fully discharged. System may be under pressure and contact with R134a may cause personal injury.

  24.  
  25. Disconnect the suction and the discharge hoses at the compressor.
  26.  
  27. Install plastic bags on the open end of the low and high side hoses.
  28.  
  29. Remove the rear compressor to bracket bolts.
  30.  
  31. Remove the front compressor to bracket bolts.
    NOTE
    Keep the compressor level during removal to avoid any oil loss from the low or high side ports.

  32.  
  33. Remove the compressor.
  34.  

To install:


NOTE
Keep the compressor level during installation to avoid any oil loss from the low or high side ports.



Click image to see an enlarged view

Fig. Install the compressor to the front bracket bolts

  1. Install the compressor to the front bracket bolts. Finger tighten only.
  2.  
  3. Install the compressor to the rear bracket bolts. Tighten the front and rear bolts to specifications.
  4.  
  5. Tighten the A/C compressor front bolts-to-bracket to 36 ft. lbs. (49 Nm).
  6.  
  7. Tighten the A/C compressor rear bolts-to-bracket to 19 ft. lbs. (25 Nm).
    NOTE
    Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.


    NOTE
    Do not lubricate the new slim line seal washer on the compressor side of the suction hose. The slim line seal washer cannot be interchanged with a typical O-ring in the A/C system. Use only suction line slim line O-rings as a replacement.

  8.  
  9. Remove the plugs or plastic bags from the suction and discharge hoses.
  10.  
  11. Install a new suction hose to the compressor slim line seal washer. Do not lubricate.
  12.  
  13. Lubricate the O-ring.
  14.  
  15. Install the O-ring for the discharge hose to the compressor.
  16.  
  17. Install the hoses to the compressor low and high side ports. Tighten the bolts to the specifications.
  18.  
  19. Tighten the suction hose-to-compressor to 19 ft. lbs. (25 Nm).
  20.  
  21. Tighten the discharge hose-to-compressor to 19 ft. lbs. (25 Nm).
  22.  
  23. Connect the compressor clutch electrical connector.
  24.  
  25. Install the accessory drive belt.
    NOTE
    Make sure gaskets are installed correctly or a leak will occur. If gaskets are removed from stubs, replace with new gaskets. Installation steps must be performed in sequence.

  26.  
  27. Install the air pipe onto the exhaust manifold studs.
  28.  
  29. Install the air pipe into the rear air compressor bracket slot.
  30.  
  31. Install the combination valve studs into the rear air compressor bracket through the air pipe flange holes.
  32.  
  33. Install and tighten the nuts on the combination valve studs, and tighten the air system combination valve nuts to 62 inch lbs.(7 Nm).
  34.  
  35. Install and tighten the nuts on the exhaust manifold studs, and tighten the air system pipe-to-exhaust manifold studs to 62 inch lbs.(7 Nm).
  36.  
  37. Install the vacuum source hose.
  38.  
  39. Install the air hose.
  40.  
  41. Set the clock to the proper time.
  42.  
  43. Evacuate, charge and leak test the A/C system.
  44.  
  45. Run the A/C performance test.
  46.  


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.  


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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