GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Corvette 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Air Conditioning Compressor Replacement

Removal Procedure

    Object Number: 296204 Size: SH
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the battery heat shield. Refer to Battery Heat Shield Replacement in Body Front End.
  3. Remove the accessory and compressor drive belts. Refer to Drive Belt Replacement - Accessory and Air Conditioning Compressor Belt Replacement in Engine Mechanical.
  4. Remove the water pump. Refer to Water Pump Replacement in Engine Cooling.
  5. Disconnect the compressor clutch electrical connector.

    6. Object Number: 82082 Size: SH
  6. Remove the compressor hose to compressor retaining bolt.

    7. Important: Cap or tape the open compressor hose immediately to prevent contamination.

  7. Disconnect the compressor hose from the compressor, discard the seal washers and cap or tape the hose end to prevent contamination.

    8. Object Number: 296274 Size: SH
  8. Remove the compressor mounting nut.
  9. Fully loosen the compressor mounting stud.

    10. Object Number: 296278 Size: SH
  10. Remove the compressor mounting bolts.
  11. Remove the compressor and the mounting stud from the vehicle.
  12. Remove the compressor mounting stud from the compressor.

    13. Object Number: 301171 Size: SH
  13. If replacing the compressor, drain and measure as much of the oil as possible from the removed compressor:
    14. 13.1. Drain the oil from both the suction and discharge ports of the removed compressor into a clean container.
    13.2. Remove the compressor crankcase oil drain bolt (1) and drain the crankcase oil from the removed compressor into the same container.
    13.3. Measure and record the amount of oil drained from the removed compressor.

    This measurement will be used during installation of the replacement compressor.

Installation Procedure

    Object Number: 301171 Size: SH
  1. Replacement compressor will come without refrigerant oil. When adding oil to this compressor, adhere closely to the following instructions:
    2. 1.1. If the amount of oil drained from the old compressor is less than or equal to 60 ml (2 oz), add 60 ml of new clean oil to the new compressor.
    1.2. If the amount of oil drained from the old compressor is greater than 60 ml (2 oz), add the same amount of new clean oil to the new compressor as drained from the old compressor.

    Object Number: 296278 Size: SH
  2. Install the compressor mounting stud to the compressor.
  3. Install the compressor into position on the compressor mounting bracket.
  4. Install the compressor mounting stud to the engine block.
  5. Install the compressor mounting bolt in the upper, forward position (net locating hole).
  6. Install the remaining compressor mounting bolts.
  7. Tighten the compressor mounting bolts in the following sequence:
    8. 7.1. Front upper, first
    7.2. Front lower, second
    7.3. Rear lower, third

    Tighten
    Tighten the compressor mounting bolts in sequence to 40 N·m (30 lb ft).


    Object Number: 296274 Size: SH
  8. Tighten the compressor mounting stud.

    9. Tighten
    Tighten the compressor mounting stud to 9 N·m (80 lb in).

  9. Install the compressor mounting nut.

    10. Tighten
    Tighten the compressor mounting nut to 40 N·m (30 lb ft).


    Object Number: 297220 Size: SH
  10. Remove the cap or tape from the compressor hose end (2).
  11. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the compressor hose (2) and the compressor (3).
  12. Lightly coat the new seal washers (1) with mineral base 525 viscosity refrigerant oil.

    13. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the seal washers to enter the refrigerant system.

  13. Carefully slide the new seal washers (1) onto the compressor hose (2) until seated.

    14. Object Number: 82082 Size: SH
  14. Install the compressor hose to the compressor.
  15. Install the compressor hose to compressor retaining bolt.

    16. Object Number: 297224 Size: SH

    Notice: Use 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.

    Important: After tightening the compressor hose (3) to the compressor (2), there should be a slight sealing washer gap (1) of approximately 1.2 mm (3/64 in) between the compressor hose (3) and the compressor (2).

  16. Tighten the compressor hose to compressor retaining bolt.

    17. Tighten
    Tighten the compressor hose to compressor retaining bolt to 26 N·m (19 lb ft).


    Object Number: 296204 Size: SH
  17. Connect the compressor clutch electrical connector.
  18. Install the water pump. Refer to Water Pump Replacement in Engine Cooling.
  19. Install the accessory and compressor drive belts. Refer to Drive Belt Replacement - Accessory and Air Conditioning Compressor Belt Replacement in Engine Mechanical.
  20. Install the battery heat shield. Refer to Battery Heat Shield Replacement in Body Front End.
  21. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  22. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  23. Check the compressor hose to compressor joint and the compressor for leaks. Refer to Leak Testing .