For 1990-2009 cars

## Air Conditioning Compressor Replacement 2.4L

### Removal Procedure

Important: When replacing a failed compressor it will be necessary to inspect the expansion orifice tube for material build up. Clean or replace as necessary. Refer to Expansion (Orifice) Tube Replacement .

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Disconnect the electrical connector from the compressor.
3. Remove the compressor hose assembly from the compressor.
4. Remove and discard the sealing washers.
5. Remove the bolts that hold the compressor to the oil pan.
6. Remove the compressor idler pulley bolts.
7. Remove the compressor.

### Installation Procedure

Important: NEW A/C compressors are shipped WITHOUT poly-alkylene glycol (PAG) oil.

1. If a new A/C compressor is being installed, add 60 ml (2 oz) of PAG oil to the compressor.
2. If reinstalling the OLD A/C compressor perform the following:

Drain, measure and record the amount of PAG oil from both the suction and discharge ports and the crankcase in the A/C compressor.

If the measured amount of PAG oil drained is less than or equal to 60 ml (2 oz), add 60 ml (2 oz) of new, clean PAG oil to the A/C compressor.

If the measured amount of PAG oil drained is greater than 60 ml (2 oz), add the same amount of new, clean PAG oil to the A/C compressor.

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 crankcase oil drain bolt (1) to the replacement compressor.

Tighten
Tighten the compressor crankcase oil drain bolt to 20 N·m (15 lb ft).

4. Install the compressor and loosely install the compressor to idler pulley bracket bolts.
5. Loosely install the oil pan to compressor bolts.

Tighten

1. Tighten the compressor-to-idler pulley bracket bolts to 50 N·m (37 lb ft).
2. Tighten the compressor-to-oil pan bolts to 50 N·m (37 lb ft).

6. Install NEW sealing washers on the compressor ports.
7. Install the compressor hose assembly.

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

8. Connect the compressor electrical connector.
9. Lower the vehicle.
10. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .

## Air Conditioning Compressor Replacement LP1

### Removal Procedure

Important: When replacing a failed compressor it will be necessary to inspect the expansion orifice tube for material build up. Clean or replace as necessary. Refer to Expansion (Orifice) Tube Replacement .

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Release the drive belt tensioner.
3. Remove the drive belt from the A/C compressor.
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
6. Disconnect the electrical connection from the compressor.
7. Remove the compressor hose set bolt from the compressor.
8. Remove the compressor hose set from the compressor.
9. Remove and discard the seal washers.
10. Remove the compressor mounting bolts.
11. Remove the compressor and the spacer.

### Installation Procedure

Important: NEW A/C compressors are shipped WITHOUT poly-alkylene glycol (PAG) oil.

Use of the incorrect PAG oil can result in compressor failure.
1. If a NEW A/C compressor is being installed, add 60 ml (2 oz) of PAG oil to the compressor. Refer to Refrigerant System Capacities .
2. If reinstalling the OLD A/C compressor perform the following:

Drain, measure and record the amount of PAG oil from both the suction and discharge ports and the crankcase in the A/C compressor.

If the measured amount of PAG oil drained is less than 60 ml (2 oz), add 60 ml (2 oz) of new, clean PAG oil to the compressor. Refer to Refrigerant System Capacities .

If the measured amount of PAG oil drained is greater than 60 ml (2 oz), add the same amount of new, clean PAG oil to the A/C compressor. Refer to Refrigerant System Capacities .

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 crankcase oil drain bolt (1) to the replacement compressor.

Tighten
Tighten the compressor crankcase oil drain bolt to 20 N·m (15 lb ft).

4. Install the compressor mounting bolts and the spacer to the compressor.
5. Install the compressor mounting bolts, the spacer, and the compressor to the engine.

Tighten
Tighten the compressor mounting bolts to 50 N·m (37 lb ft).

6. Install NEW seal washers to the compressor ports.
7. Install the compressor hose assembly and the bolt to the compressor.

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

8. Connect the electrical connection to the compressor.
9. Install the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
10. Lower the vehicle.
11. Release the drive belt tensioner.
12. Install the drive belt to the A/C compressor.
13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .