Tracker 2000-2004

Removal & Installation

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1.6L & 2.0L Engines




CAUTION
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 replacing the compressor, drain the oil and measure the amount. Add this amount when installing a new compressor. New compressors are shipped with 120 ml (4.0 fl oz) of oil. Drain oil from the new compressor as necessary in order to ensure that the removed amount of oil and the added amount of oil are equal.

  1. Discharge and recover the refrigerant.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove 1 bolt and the suction hose from the compressor.
  6.  
  7. Remove 1 bolt and the discharge hose from the compressor.
  8.  
  9. Discard the O-rings.
  10.  
  11. Cap all of the refrigerant line openings in order to keep out dirt and moisture.
  12.  
  13. Disconnect the compressor clutch electrical connector.
  14.  
  15. Perform the following if the vehicle is equipped with the 1.6L engine:
    1. Remove the compressor upper mounting bolt.
    2.  
    3. Remove the compressor lower mounting bolt.
    4.  
    5. Remove the compressor lower mounting nut and bolt.
    6.  
    7. Remove the compressor from the vehicle, while disengaging the compressor drive belt from the compressor clutch pulley.
    8.  

  16.  
  17. Perform the following if the vehicle is equipped with the 2.0L engine:
    1. Remove the compressor drive belt from the compressor pulley.
    2.  
    3. Remove the 3 compressor mounting bolts.
    4.  
    5. Remove the compressor from the vehicle.

      Click image to see an enlarged view

      Fig. A/C compressor removal/installation-1.6L engine



      Click image to see an enlarged view

      Fig. A/C compressor removal/installation-2.0L engine

    6.  

  18.  

To install:

  1. Perform the following if the vehicle is equipped with the 1.6L engine:
    1. Install the compressor to the vehicle, while engaging the compressor drive belt to the compressor clutch pulley.
    2.  
    3. Install the compressor upper mounting bolt (1).
    4.  
    5. Install the compressor lower mounting bolt.
    6.  
    7. Install the compressor lower mounting nut and bolt and tighten to 17 ft. lbs. (23 Nm).
    8.  

  2.  
  3. Perform the following if the vehicle is equipped with the 2.0L engine:
    1. Install the compressor to the vehicle. Secure the compressor with the 3 mounting bolts and tighten to 17 ft. lbs. (23 Nm).
    2.  

  4.  
  5. Install the compressor drive belt. Adjust the belt tension.
  6.  
  7. Coat new discharge and suction hose O-rings with mineral base 525 viscosity refrigerant oil.
  8.  
  9. Connect the discharge and the suction hoses to the compressor. Secure with two bolts and tighten to 26 inch lbs. (35 Nm).
  10.  
  11. Connect the compressor clutch electrical connector.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Evacuate and recharge the air conditioning system.
  16.  
  17. Operate the A/C system and test for refrigerant leaks.
  18.  

2.5L Engine




CAUTION
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 replacing the compressor, drain the oil and measure the amount. Add this amount when installing a new compressor. New compressors are shipped with 120 ml (4.0 fl oz) of oil. Drain oil from the new compressor as necessary in order to ensure that the removed amount of oil and the added amount of oil are equal.

  1. Discharge and recover the refrigerant.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the power steering Pressure switch connector.
  6.  
  7. Remove the 3 bolts from the power steering pump and position out of the way.
  8.  
  9. Remove 1 bolt and the suction hose from the compressor.
  10.  
  11. Remove 1 bolt and the discharge hose from the compressor.
  12.  
  13. Discard the O-rings.
  14.  
  15. Cap all of the refrigerant line openings in order to keep out dirt and moisture.
  16.  
  17. Disconnect the compressor clutch electrical connector.
  18.  
  19. Remove the compressor drive belt from the compressor pulley.
  20.  
  21. Remove the 3 compressor mounting bolts.
  22.  
  23. Remove the compressor from the vehicle.

    Click image to see an enlarged view

    Fig. A/C compressor removal/installation- 2.5L engine

  24.  

To install:

  1. Install the compressor to the vehicle. Secure the compressor with the 3 bolts and tighten to 17 ft. lbs. (23 Nm).
  2.  
  3. Coat new discharge and suction hose O-rings with mineral base 525 viscosity refrigerant oil.
  4.  
  5. Connect the discharge and the suction hoses to the compressor. Secure with two bolts and tighten to 26 ft. lbs. (35 Nm).
  6.  
  7. Connect the compressor clutch electrical connector.
  8.  
  9. Install the power steering pump and secure with the 3 bolts. Tighten the power steering pump bolts to 18 ft. lbs. (25 Nm).
  10.  
  11. Connect the power steering Pressure switch connector.
  12.  
  13. Install the compressor drive belt.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Evacuate and recharge the air conditioning system.
  18.  
  19. Operate the A/C system and test for refrigerant leaks.
  20.  

 
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