GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1998 🢒 Metro 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Air Conditioning Compressor Replacement

Removal Procedure
  1. Discharge and recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

    2. Object Number: 354646 Size: SH
  2. Disconnect the compressor clutch electrical connector (6).
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.

    5. Object Number: 354744 Size: SH
  5. Loosen the idler pulley locknut (4).
  6. Loosen the idler pulley adjusting bolt (1).

    7. Object Number: 354647 Size: SH
  7. Remove the compressor drive belt (2) from the clutch pulley.

    8. Object Number: 354691 Size: SH
  8. Remove 1 bolt (3) and the discharge hose (1) from the compressor.
  9. Remove 1 bolt (3) and the suction hose (4) from the compressor.
  10. Discard the O-rings.

    11. Object Number: 354693 Size: MH
  11. Remove the 3 bolts (1,4,5) and the compressor from the vehicle.
  12. Cap all of the refrigerant line openings in order to keep dirt and moisture out of the system.

Installation Procedure

    Important: When installing a new compressor, add 90 cc (3.0 fl oz) of refrigerant oil to the refrigeration system.


    Object Number: 354693 Size: MH

    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: The proper torque sequence is essential in order to prevent damage to the compressor or the compressor bracket.

  1. Install the compressor to the compressor bracket. Secure the compressor with 3 bolts (1,4,5). Tighten the bolts in the following sequence:
    2. 1.1. Bolt (4)
    1.2. Bolt (5)
    1.3. Bolt (1)
  2. Tighten the bolts

    3. Tighten
    Tighten the compressor bolts to 22.5-27.4 N·m (16.5-20.1 lb ft).


    Object Number: 354743 Size: SH
  3. Install the compressor drive belt (2).
  4. Ensure that the belt is properly aligned on the compressor, power steering (if equipped) and crankshaft pulleys.

    5. Object Number: 354744 Size: SH
  5. Adjust the drive belt tension.
    6. 5.1. Turn the idler pulley adjusting bolt (1) to obtain 7-9 mm (0.28-0.35 in) belt deflection at 10 kg (22 lbs) of force (thumb pressure).
    5.2. Tighten the idler pulley locknut (4).

    Tighten
    Tighten the idler pulley locknut to 44.1-49 N·m (32.4-36 lb ft).


    Object Number: 354646 Size: SH
  6. Connect the compressor clutch electrical connector (6).
  7. Secure the electrical connector wire with the clamps (5).

    8. Object Number: 354691 Size: SH
  8. Coat the new discharge and suction hose O-rings with 525 viscosity mineral oil.
  9. Install the discharge and suction hoses (1,4) to the compressor.

    10. Tighten
    Tighten the compressor discharge and suction hose bolts to 9.8 N·m (86.74 lb ft).

  10. Install the engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
  11. Lower the vehicle.
  12. Evacuate and recharge the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging .
  13. Operate the A/C system and inspect for refrigerant leaks. Refer to Leak Testing .