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For 1990-2009 cars only

Air Conditioning Compressor Replacement RPOs L61, LE5

Tools Required

    • J 39400-A Halogen Leak Detector
    • J 44811 Accessory Belt Tensioner Unloader

Removal Procedure

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the front fender liner. Refer to Front Fender Liner Replacement in Body Front End.

  4. Object Number: 854300  Size: SH
  5. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
  6. Remove the drive belt.

  7. Object Number: 872569  Size: SH
  8. Disconnect the electrical connector from the compressor.

  9. Object Number: 865182  Size: SH
  10. Remove the compressor and condenser hose assembly bolt from the compressor.
  11. Remove the compressor and condenser hose assembly from the compressor.
  12. Remove and discard the sealing washers.

  13. Object Number: 872535  Size: SH
  14. Remove the compressor mounting bolts.
  15. Remove the compressor.

Installation Procedure

    Important: NEW CVC 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.

  1. If you are replacing the compressor, refer to Air Conditioning Compressor Oil Balancing .
  2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 872535  Size: SH
  3. Install the compressor and the bolts to the engine.
  4. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 865182  Size: SH
  5. Install new sealing washers on the hose fittings. Refer to Sealing Washer Replacement .
  6. Install the hose assembly to the compressor.
  7. Install the assembly bolt.
  8. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 872569  Size: SH
  9. Connect the compressor electrical connector.

  10. Object Number: 854300  Size: SH
  11. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
  12. Install the drive belt.
  13. Install the front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  14. Lower the vehicle.
  15. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  16. Leak test the fittings using J 39400-A .

Air Conditioning Compressor Replacement RPO LSJ

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  4. Remove the drive belt. Refer to Drive Belt Replacement .

  5. Object Number: 872569  Size: SH
  6. Disconnect the electrical connector from the compressor.

  7. Object Number: 865182  Size: SH
  8. Remove the compressor and condenser hose assembly bolt from the compressor.
  9. Remove the compressor and condenser hose assembly from the compressor.
  10. Remove and discard the sealing washers.

  11. Object Number: 1403204  Size: SH
  12. Remove the auxiliary intercooler pump bolts and position the pump toward the driver side of the vehicle.

  13. Object Number: 1609034  Size: SH
  14. Remove the compressor mounting bolts.
  15. Remove the compressor.

Installation Procedure

    Important: NEW CVC 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.

  1. If you are replacing the compressor, refer to Air Conditioning Compressor Oil Balancing .
  2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1609034  Size: SH
  3. Install the compressor and the bolts to the engine.
  4. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 865182  Size: SH
  5. Install new sealing washers on the hose fittings. Refer to Sealing Washer Replacement .
  6. Install the hose assembly to the compressor.
  7. Install the assembly bolt.
  8. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 872569  Size: SH
  9. Connect the compressor electrical connector.

  10. Object Number: 1403204  Size: SH
  11. Install the auxiliary intercooler pump.
  12. Tighten
    Tighten the pump bolt to 10 N·m (88 lb in).

  13. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.0L.
  14. Install the front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  15. Lower the vehicle.
  16. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  17. Leak test the fittings using J 39400-A .