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 - 3.0L (L81) or 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 engine harness from the compressor.



5. On L81 vehicles, disconnect the oxygen sensor from the engine harness.



6. On L81 vehicles, remove the oxygen sensor from the exhaust.



7. Loosen the bolt that secures the suction/discharge to the compressor by 7-8 turns, and remove the block from the compressor by moving the block forward, then up.
8. Remove and discard the sealing washers.
9. Install the shipping cap on the compressor hose assembly to prevent moisture or contamination.
10. Install the compressor shipping cap before removal to prevent oil spillage and contamination.



11. Remove the bolts that secure the compressor to the engine block. Remove the compressor.

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 caps on the compressor to prevent oil spillage during installation.




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 to the engine block bracket with the attachment bolts.

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




4. Remove the shipping cap from the compressor and the compressor hose assembly. Install new seal washers. Refer to Sealing Washer Replacement .
5. Install the compressor hose assembly to the compressor. Tighten the attachment bolt while holding the hose block flush.

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




6. On L81 vehicles, install the oxygen sensor to the exhaust pipe.

Tighten
Tighten the bolts to 45 N·m (33 lb ft).




7. On L81 vehicles, connect the oxygen sensor to the engine wire harness.



8. Connect the engine wire harness to the compressor.
9. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.0L (L81) or to Drive Belt Replacement in Engine Mechanical - 2.2L (L61).
10. Lower vehicle.
11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
12. Use J 39400-A to leak test the fittings .