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.
- Recover the refrigerant.
- Remove the accessory drive belt.
- Raise and safely support the vehicle.
Disconnect the engine harness from the compressor.
- Loosen the bolt that secures the suction/discharge to the compressor by 7-8 turns, and remove the block from the compressor by moving the block forward, then up.
- Remove and discard the sealing washers.
- Install the shipping cap on the compressor hose assembly to prevent moisture or contamination.
- Install the compressor shipping cap before removal to prevent oil spillage and contamination.
- Remove the bolts that secure the compressor to the engine block.
- Remove the A/C compressor.
Do NOT mix refrigerant oils. Use of incorrect refrigerant oil may cause compressor failure. This compressor uses a low viscosity refrigerant oil, Saturn P/N 22695048.
NEW 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.
Drain and measure as much of the refrigerant oil as possible from the removed compressor.
- Drain the oil from both the suction and discharge ports of the removed compressor into a clean, graduated container. Rotate the compressor shaft to assist in draining the compressor.
Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
NOTEDuring the oil removal procedure, the condition of the oil should be evaluated. Compressor oil never breaks down unless something is wrong with the compressor or air conditioning (A/C) system. If one or more of the following conditions exist, replace the compressor and receiver dehydrator. Inspect the PAG oil for the following conditions:
The color of the oil is dark brown or black
Properly discard the used refrigerant oil.
NOTEThe refrigerant oil in the A/C system must be balanced during compressor replacement.
The replacement compressor is shipped with 4.0 oz. (120 ml) of refrigerant oil.
If replacing the compressor, 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 4.0 oz. (120 ml), leave the 4.0 oz (120 ml) in the replacement compressor.
Install caps on the compressor to prevent oil spillage during installation.
WARNINGUse 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.
- Install the compressor to the engine block bracket with the attachment bolts.
- Tighten the bolts to 16 ft. lbs. (22 Nm).
- Remove the shipping cap from the compressor and the compressor hose assembly. Install new seal washers.
- Install the compressor hose assembly to the compressor. Tighten the attachment bolt while holding the hose block flush.
Tighten the bolts to 20 ft. lbs. (27 Nm).
NOTEAfter tightening the A/C components, there should be a slight sealing washer gap of approximately 3 / 64 inch (1.2mm) between the A/C line and the A/C component.
- Connect the engine wire harness to the compressor.
- Install the accessory drive belt.
- Evacuate and charge the refrigerant system.
- Use J 39400-A, Halogen Leak Detector or equivalent, to leak test the fittings.