Air Conditioning Compressor Replacement 2.2L

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise.
3. Reposition the drive belt from the A/C compressor.
4. Slowly release the tension on the drive belt tensioner arm.
5. Disconnect the electrical connectors as necessary.

Important: Some system pressure may still exist in the A/C compressor crankcase after you evacuate the system.

6. Remove the compressor hose assembly.



7. Remove the compressor mounting bolts (2) from the bottom, front of the A/C compressor (1).



8. Remove the compressor rear bracket bolts.
9. Remove the compressor from the brackets.
10. If replacing the compressor, balance the refrigerant oil. Refer to Compressor Oil Balancing in Heating, Ventilation and Air Conditioning.

1. Install the compressor to the brackets.

Notice: Refer to Fastener Notice in the Preface section.




2. Install the compressor mounting bolts (2) to the A/C compressor (1).

Tighten
Tighten the bolts to 50 N·m (37 lb ft).




3. Install the compressor rear bracket bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

4. Install the compressor hose assembly.
5. Connect the electrical connectors as necessary.
6. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise.
7. Reposition the drive belt to the A/C compressor.
8. Slowly release the tension on the drive belt tensioner arm.
9. Inspect for the drive belt being properly installed on the pulleys.
10. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
11. Leak test the fittings components using the J 39400-A .

Air Conditioning Compressor Replacement 4.3L

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 4.3L.
3. Remove the drive belt.



4. Disconnect the A/C compressor clutch coil electrical connector (1).



5. Disconnect the A/C high pressure switch electrical connector (2).

Important: Do not disconnect the compressor hose assembly from the condenser or the accumulator.

6. Remove the compressor hose assembly from the compressor.
7. Remove the compressor sealing washers and discard.
8. Remove the nut and throttle control cable bracket from the throttle body.



9. Remove the compressor mounting bolts.
10. Remove the compressor from the vehicle.
11. If replacing the compressor, balance the refrigerant oil. Refer to Compressor Oil Balancing .

1. Install the new compressor to the vehicle.

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.

2. Install the compressor mounting bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

3. Install the throttle control cable bracket and nut to the throttle body.

Tighten
Tighten the nut to 12 N·m (106 lb in).

4. Install new compressor hose assembly sealing washers. Refer to Compressor Sealing Washers Replacement .
5. Install the compressor hose assembly to the compressor.



6. Connect the A/C high pressure switch electrical connector (2).



7. Connect the A/C compressor clutch coil electrical connector (1).
8. Install the drive belt.
9. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 4.3L.
10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
11. Leak test the fittings components using the J 39400-A .