Air Conditioning Compressor Replacement L61

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.2L (L61).
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



4. Disconnect the electrical connector from the compressor.



5. Remove the compressor hose bolt from the compressor.
6. Remove the compressor hose from the compressor.
7. Remove and discard the O-rings from the compressor. Refer to O-Ring Replacement .
8. Install a shipping cap to the compressor hose to prevent moisture or contamination from entering the A/C system.
9. Install a shipping cap to the compressor to prevent oil spillage during compressor removal.



10. Remove the compressor bolts from the engine.
11. Remove the compressor from the vehicle.

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 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 replacing the compressor, refer to Compressor Oil Balancing .
2. Install a shipping cap to the compressor to prevent oil spillage during installation.



3. Install the 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.

4. Install the compressor bolts to the engine.

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




5. Remove the shipping caps from the compressor and the compressor hose.
6. Install new O-rings to the compressor. Refer to O-Ring Replacement .
7. Install the compressor hose to the compressor.
8. Install the compressor hose bolt to the compressor.

Tighten
Tighten the bolt to 27 N·m (20 lb ft).




9. Connect the electrical connector to the compressor.
10. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.2L (L61).
11. Lower vehicle.
12. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging .
13. Test the affected A/C joints for leaks using J 39400-A .

Air Conditioning Compressor Replacement L66

Tools Required

J 39400-A Halogen Leak Detector

Important: Performing this procedure will require replacement of the forward engine frame bolts.

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 3.5L (L66).
3. Remove the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical -- 3.5L (L66).
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Disconnect the electrical connector from the compressor.



6. Remove the compressor hose bolt from the compressor.
7. Remove the compressor hose from the compressor.
8. Remove and discard the O-rings from the compressor. Refer to O-Ring Replacement .
9. Install a cap to the compressor hose to prevent moisture or contamination from entering the A/C system.



10. Place an adjustable jack stand or a lifting device under the front edge of the engine frame.
11. Loosen, but do not remove, the front engine frame mounting bolts.
12. Lower the forward edge of the engine frame approximately 12.7 mm (0.5 in).
13. Remove the compressor bolts from the engine.
14. Remove the compressor from the vehicle.

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 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 replacing the compressor, refer to Air Conditioning Compressor Oil Balancing .



2. Install the compressor to the vehicle.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the compressor bolts to the engine.

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

4. Raise the forward edge of the engine frame.
5. Remove and discard the right hand front engine frame bolt.
6. Install a new right hand front engine frame bolt.
7. Remove and discard the left hand front engine frame bolt.
8. Install a new left hand front engine frame bolt.
9. Tighten the engine frame bolts to the body.

Tighten
Tighten the bolts to 155 N·m (114 lb ft).

10. Remove the adjustable jack stand or lifting device from the front edge of the engine frame.



11. Remove the caps from the compressor and the compressor hose.
12. Install new O-rings to the compressor. Refer to O-Ring Replacement .
13. Install the compressor hose to the compressor.
14. Install the compressor hose bolt to the compressor.

Tighten
Tighten the bolt to 27 N·m (20 lb ft).




15. Connect the electrical connector to the compressor.
16. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
17. Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical -- 3.5L (L66).
18. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 3.5L (L66).
19. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging .
20. Test the affected A/C joints for leaks using J 39400-A .