Air Conditioning Compressor Replacement 2.2L

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.2L.
3. Disconnect the electrical connectors as necessary.

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

4. Remove the compressor suction/discharge hose assembly. Refer to Compressor Hose Assembly Replacement .



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



6. Remove the compressor rear bracket bolts.
7. Remove the compressor from the brackets.
8. Drain and measure the compressor oil.
9. Inspect the oil for contamination or metal particles.

1. Fill the replacement compressor with oil. Refer to Refrigerant Oil Distribution Specifications for the proper amount.
2. Install the compressor to the brackets.




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.

3. Install the compressor rear bracket bolts and the mounting bolts (2) to the A/C Compressor (1).

Tighten

1. Tighten the compressor mounting bolts to 50 N·m (37 lb ft).
2. Tighten the compressor rear bracket bolts to 25 N·m (18 lb ft).



4. Install the compressor suction/discharge hose assembly. Refer to Compressor Hose Assembly Replacement .
5. Connect the electrical connectors as necessary.
6. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.2L.
7. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging .

Air Conditioning Compressor Replacement 4.3 L

Tools Required

J 39400-A Halogen Leak Detector

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



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 suction/discharge hose assembly from the condenser or the accumulator.

6. Remove the compressor suction/discharge hose assembly from the compressor. Refer to Compressor Hose Assembly Replacement .
7. Remove the compressor sealing washers and discard. Refer to Compressor Sealing Washers Replacement .
8. Disconnect the accelerator control cable from the throttle bracket. Refer to Accelerator Control Cable Replacement in Engine Controls - 4.3 L.
9. If equipped, disconnect the cruise control cable from the throttle bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
10. Remove the nut and throttle control cable bracket from the throttle body.



11. Remove the 4 compressor mounting bolts.
12. Remove the compressor from the accessory mounting bracket.
13. Drain and measure the compressor oil.
14. Inspect the oil for contamination or metal particles.

Important: Replacement compressors are shipped without oil.

1. Add oil to the new compressor by following the instruction sheets shipped with the compressor. If the instruction sheets are not available, do the following:

1.1.	Drain the refrigerant oil from the removed compressor into a clean, calibrated container.

1.2.	Record the amount of oil removed from the old compressor.

1.3.	If the amount of oil drained from the old compressor is less than or equal to 60 ml (2 fl oz), add 60 ml (2 fl oz) of new 525 viscosity refrigerant oil to the new compressor.

1.4.	If the amount of oil drained from the old compressor is greater than 60 ml (2 fl oz), add the same amount of new 525 viscosity refrigerant oil to the new compressor.




2. Install the new compressor to the accessory mounting bracket.

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.

3. Install the 4 compressor mounting bolts.

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

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

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

5. If equipped, connect the cruise control cable to the throttle cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
6. Connect the accelerator control cable to the throttle cable bracket. Refer to Accelerator Control Cable Replacement in Engine Controls - 4.3 L.
7. Install new compressor and suction/discharge sealing washers. Refer to Compressor Sealing Washers Replacement .
8. Install the compressor suction/discharge hose assembly to the compressor. Refer to Compressor Hose Assembly Replacement .



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



10. Connect the A/C compressor clutch coil electrical connector (1).
11. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 4.3 L.
12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls - 4.3 L
13. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fitting(s) of the repaired or reinstalled components using the J 39400-A .