For 1990-2009 cars

## Air Conditioning Compressor Replacement L61

#### Tools Required

J 39400-A Halogen Leak Detector

### Removal Procedure

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 connector from the compressor.
7. Remove the Compressor hose assembly bolt from the compressor.
8. Remove the Compressor hose assembly from the compressor.
9. Remove and discard the sealing washers.
10. Remove the compressor mounting bolts.
11. Remove the compressor.
12. If replacing the compressor:

12.1. | Drain the oil from both the suction and the discharge ports into a clean container.

12.2. | Remove the compressor crankcase oil drain plug and drain the crankcase oil into the same container.

12.3. | Measure and record the amount of oil drained from the compressor. This measurement will be used during the compressor installation procedure.

12.4. | Properly discard the used PAG oil.

### Installation Procedure

Notice: Do not mix refrigerant oils. Use of incorrect refrigerant oil will cause compressor failure.

The CVC compressor uses a low viscosity refrigerant oil, GM P/N 12378526 (Canadian P/N 88900060).

Important: NEW CVC compressor assemblies are shipped with a full poly-alkylene glycol (PAG) refrigerant oil charge. Use of the incorrect PAG oil can result in compressor failure.

1. Drain the Pag oil from the new compressor into a clean calibrated measuring container. Drain from the crankcase and from the rear head ports.

If the amount of old oil drained is less than or equal to 75 ml (2.5 oz), add 75 ml of new oil into the new compressor through the crankcase bolt hole.

If the amount of old oil drained is greater than 75 ml (2.5 oz), add the equivalent amount of new oil into the new compressor through the crankcase bolt hole.

2. 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 crankcase oil drain plug to the compressor.

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

4. Rotate the clutch driver 3 times to lubricate the internal swashplate and the piston shoes.
5. Install the bolts and the compressor to the engine.

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

6. Install NEW sealing washers on the compressor ports.
7. Install the A/C compressor hose assembly to the compressor.
8. Install the A/C compressor hose assembly bolt.

Tighten
Tighten the bolt to 11 N·m (8 lb ft).

9. Connect the compressor electrical connector.
10. Lower the vehicle.
11. Install the drive belt on the A/C compressor
12. Release the drive belt tensioner.
13. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fittings of the repaired or reinstalled component using the J 39400-A .

## Air Conditioning Compressor Replacement LP1

#### Tools Required

J 39400-A Halogen Leak Detector

### Removal Procedure

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 A/C compressor hose assembly bolt from the compressor.
8. Remove the A/C compressor hose assembly from the compressor.
9. Remove and discard the seal washers.
10. Remove the compressor mounting bolts.
11. Remove the compressor and the spacer.
12. If replacing the compressor:

12.1. | Drain the oil from both the suction and the discharge ports into a clean container.

12.2. | Remove the compressor crankcase oil drain plug and drain the crankcase oil into the same container.

12.3. | Measure and record the amount of oil drained from the compressor. This measurement will be used during the compressor installation procedure.

12.4. | Properly discard the used PAG oil.

### Installation Procedure

Important: NEW A/C compressors are shipped without a poly-alkylene glycol (PAG) refrigerant oil charge . 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 .

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.

2. Install the compressor crankcase oil drain bolt (1) to the compressor.

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

3. Install the compressor mounting bolts and the spacer to the compressor.
4. Install the compressor to the engine.

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

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

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

7. Connect the electrical connection to the compressor.
8. Install the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
9. Lower the vehicle.
10. Install the drive belt to the A/C compressor.
11. Release the drive belt tensioner.
12. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
13. Leak test the fittings of the repaired or reinstalled component using the J 39400-A .