For 1990-2009 cars

#### Tools Required

J 39400-A Halogen Leak Detector

### Removal Procedure

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Remove the intake air resonator. Refer to Intake Air Resonator Replacement in Engine Controls.
3. Remove the compressor hose bracket to oil pan bolt.
4. Remove the compressor hose clamp to air pipe bracket bolt (1).
5. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Remove the front compressor bolts.
8. Remove the rear compressor bolts (1).
9. Disconnect the compressor electrical connector.
10. Lower the vehicle.
11. Slide the compressor forward.
12. Remove the compressor hose bolt.
13. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
14. Remove the compressor hose seal washers.
15. Lower the vehicle.
16. Remove the compressor.
17. If replacing the compressor, drain and measure as much of the oil as possible from the removed compressor:

17.1. | Drain the oil from both the suction and discharge ports of the removed compressor into a clean container.

17.2. | Remove the compressor crankcase oil drain bolt (1) and drain the crankcase oil from the removed compressor into the same container.

17.3. | Measure and record the amount of oil drained from the removed compressor.

This measurement will be used during installation of the replacement compressor.

### Installation Procedure

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.

1. The replacement compressor is shipped without refrigerant oil. Refer to Refrigerant System Capacities for PAG oil capacity.

If replacing the compressor use the following oil fill procedure.

• | Remove the compressor crankcase drain plug

• | Add the PAG oil through the compressor drain hole

• | Install the compressor drain plug

• | Tighten the compressor drain plug.

Tighten
Tighten the drain plug to 20 N·m (15 lb ft).

2. Install the compressor.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Install the compressor hose seal washers:

• | Use new seal washers.

• | Lubricate the seal washers with mineral oil, 525 viscosity.

5. Install the compressor hose.
6. Install the compressor hose bolt.
7. Lower the vehicle.
8. Tighten the compressor hose bolt.

Tighten
Tighten the bolt to 33 N·m (24 lb ft).

9. Position the compressor to the mounting bracket.
10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
11. Install the rear compressor mounting bolts (1).
12. Install the front compressor mounting bolts.
13. Tighten the compressor mounting bolts.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).

14. Connect the compressor electrical connector.
15. Lower the vehicle.
16. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
17. Install the compressor hose bracket to oil pan bolt.

Tighten
Tighten the bolt to 8 N·m (71 lb in).

18. Install the compressor hose clamp to air pipe bracket bolt (1).

Tighten
Tighten the bolt to 8 N·m (71 lb in).

19. Install the intake air resonator. Refer to Intake Air Resonator Replacement in Engine Controls.
20. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
21. Leak test the fittings of the component using the J 39400-A .