GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Conditioning Compressor Replacement

Air Conditioning Compressor Replacement 2.2L (L61), 2.4L (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 right side engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.

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

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

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

    10. Object Number: 872535 Size: SH
  10. Remove the compressor mounting bolts.
  11. Remove the compressor.

Installation Procedure

    Notice: Do NOT mix refrigerant oils. Use of incorrect refrigerant oil will cause compressor failure. This compressor uses a low viscosity refrigerant oil, Saturn P/N 22695048.

    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
  2. Install the compressor and the bolts to the engine.

    3. Tighten
    Tighten the bolts to 22 N·m (16 lb ft).


    Object Number: 865182 Size: SH
  3. Install new sealing washers on the hose fittings. Refer to Sealing Washer Replacement .
  4. Install the hose assembly to the compressor.
  5. Install the assembly bolt.

    6. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


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

    7. Object Number: 854300 Size: SH
  7. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
  8. Install the drive belt.
  9. Install the right side engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
  10. Lower the vehicle.
  11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  12. Leak test the fittings using J 39400-A .