For 1990-2009 cars

## Air Conditioning Compressor Replacement LSJ

#### Tools Required

J 39400-A Halogen Leak Detector

### Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the right front fender liner. Refer to Front Fender Liner Replacement .
4. Remove the drive belt. Refer to Drive Belt Replacement .
5. Disconnect the electrical connector from the compressor.
6. Remove the compressor and condenser hose assembly bolt from the compressor.
7. Remove the compressor and condenser hose assembly from the compressor.
8. Remove and discard the sealing washers.
9. Remove the auxiliary intercooler pump bolts and position the pump toward the driver side of the vehicle.
10. Remove the compressor mounting bolts.
11. Remove the compressor.

### Installation Procedure

Important: NEW CVC 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 you are replacing the compressor, refer to Air Conditioning Compressor Oil Balancing .

Notice: Refer to Fastener Notice in the Preface section.

2. Install the compressor and the bolts to the engine.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

3. Install new sealing washers on the hose fittings. Refer to Sealing Washer Replacement .
4. Install the hose assembly to the compressor.
5. Install the assembly bolt.

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

6. Connect the compressor electrical connector.
7. Install the auxiliary intercooler pump.

Tighten
Tighten the pump bolt to 10 N·m (88 lb in).

8. Install the drive belt. Refer to Drive Belt Replacement .
9. Install the front fender liner. Refer to Front Fender Liner Replacement .
10. Lower the vehicle.
11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
12. Leak test the fittings using J 39400-A .

## Air Conditioning Compressor Replacement L61, LE5 - First Design

#### Tools Required

• | J 39400-A Halogen Leak Detector

• | J 44811 Accessory Belt Tensioner Unloader

### Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the front fender liner. Refer to Front Fender Liner Replacement .
4. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
5. Remove the drive belt.
6. Disconnect the electrical connector from the compressor.
7. Remove the compressor and condenser hose assembly bolt from the compressor.
8. Remove the compressor and condenser hose assembly from the compressor.
9. Remove and discard the sealing washers.
10. Remove the compressor mounting bolts.
11. Remove the compressor.

### Installation Procedure

Important: NEW CVC 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 you are replacing the compressor, refer to Air Conditioning Compressor Oil Balancing .

Notice: Refer to Fastener Notice in the Preface section.

2. Install the compressor and the bolts to the engine.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

3. Install new sealing washers on the hose fittings. Refer to Sealing Washer Replacement .
4. Install the hose assembly to the compressor.
5. Install the assembly bolt.

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

6. Connect the compressor electrical connector.
7. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
8. Install the drive belt.
9. Install the front fender liner. Refer to Front Fender Liner Replacement .
10. Lower the vehicle.
11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
12. Leak test the fittings using J 39400-A .

## Air Conditioning Compressor Replacement L61, LE5 - Second Design

#### Special Tools

• | J 39400-A Halogen Leak Detector

• | J 44811 Accessory Belt Tensioner Unloader

### Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove the right side engine splash shield. Refer to Engine Splash Shield Replacement - Right Side.
4. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
5. Remove the drive belt.
6. Disconnect the electrical connector from the compressor.
7. Remove the compressor and condenser hose assembly bolt from the compressor.
8. Remove the compressor and condenser hose assembly from the compressor.
9. Remove and discard the sealing washers.
10. Remove the compressor mounting bolts.
11. Remove the compressor.

### Installation Procedure

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 you are replacing the compressor, refer to Air Conditioning Compressor Oil Balancing.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the compressor and the bolts to the engine.

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

3. Install new sealing washers on the hose fittings. Refer to Sealing Washer Replacement.
4. Install the hose assembly to the compressor.
5. Install the assembly bolt.

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

6. Connect the compressor electrical connector.
7. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
8. Install the drive belt.
9. Install the right side engine splash shield. Refer to Engine Splash Shield Replacement - Right Side.
10. Lower the vehicle.
11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
12. Leak test the fittings using J 39400-A .