For 1990-2009 cars

## Air Conditioning Compressor Replacement 3.4L

Refer to the following procedures for A/C compressor service:

• | V5 Air Conditioning Compressor Service

• | R134a Unit Repair

### Removal Procedure

#### Tools Required

J 39500-B R-134a Refrigerant Recovery, Recycling and Recharging (ACR4) System

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Use the J 39500-B in order to recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Remove the drive belt. Refer Drive Belt Replacement Engine Mechanical - 3.4L.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the lower closeout panel.
6. Disconnect the electrical connection at the compressor (2).
7. Disconnect the compressor/condenser hose at the rear of the compressor (2). Discard the seals.
8. Remove the compressor attaching bolts (1).
9. Remove the compressor (2).
10. Drain the compressor oil.
11. Measure the compressor oil.

### Installation Procedure

1. Drain the compressor oil from the new compressor.
2. Refill the compressor with the same amount of oil that was drained from the old compressor.

If less than 30 ml (1 oz) was drained from the old compressor, add 60 ml (2 oz).

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.

Important: Repairs to the following areas require the loosening of some A/C bracket bolts:

• | The A/C compressor (2)

• | The A/C belt system

In order to prevent future torque loss after retightening the bolts, perform the following steps:

• | Replace the bolt with an appropriate new bolt.

• | Replace the stud with an appropriate new stud.

• | Apply Loctite® 242 or the equivalent to the bolt or stud threads.

| Follow the package instructions in order to achieve the best retention.

3. Install the following components:

• | The compressor (2)

• | The compressor attaching bolts (1)

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

4. Connect the compressor/condenser hose to the rear of the compressor (2). Use new, unlubricated sealing washers.

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

5. Connect the electrical connection to the compressor (2).
6. Install the lower closeout panel.
7. Lower the vehicle.
8. Install the serpentine belt.
9. Connect the negative battery cable.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

10. Use the J 39500-B in order to evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .

## Air Conditioning Compressor Replacement 2.4L

### Removal Procedure

#### Tools Required

J 39500-B A/C Refrigerant Recovery, Recharging, and Recycling Station

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the serpentine belt.
3. Recover the A/C system. Refer to Refrigerant Recovery and Recharging .
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the engine splash shield.
6. Remove the compressor hose assembly. Discard the sealing washers.
7. Plug or tape the compressor/condenser hose end in order to prevent moisture contamination.
8. Disconnect the clutch electrical connector from the compressor (4).
9. Remove the compressor bolts (1,2,3,5).

Important: If you replace the compressor (4), refer to Refrigerant Oil Distribution .

10. Remove the compressor (4) from the engine assembly (6).

### Installation Procedure

#### Tools Required

J 39500-B A/C Refrigerant Recovery, Recharging, and Recycling Station

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. Install the compressor (4) with mounting bolts (1,2,3,5).

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

2. Connect the electrical connector.
3. Install the compressor hose assembly using the new sealing washers.

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

4. Install the engine splash shield.
5. Lower the vehicle.
6. Install the drive belt. Refer to the underhood label for routing.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

7. Connect the negative battery cable.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
9. Perform a leak test. Refer to Leak Testing .
10. Test the system operation.