For 1990-2009 cars

## Air Conditioning Compressor Replacement L61

### Removal Procedure

1. Disconnect the negative battery cable

Important: Verifying the purity of the refrigerant with a purity identifier before recovery is recommended.

2. Recover the refrigerant using an approved refrigerant recovery system. Measure the amount of oil lost during recovery and record the amount.

Caution: Refer to HVAC Compressor Lines/Hoses Caution in the Preface section.

Notice: When servicing the compressor, keep dirt and foreign material from getting on or into the compressor parts and system. Clean tools and clean work area are important for proper service. The compressor connections and the outside of the compressor should be cleaned before any ON CAR repairs, or before removal of the compressor. The parts must be kept clean at all times and any parts to be assembled should be cleaned with a non-petroleum based solvent and dried with air. Use only lint free cloths to wipe parts. Do not allow solvent to enter compressor or hoses.

3. Remove the suction pipe and the seal washer from compressor.
4. Install a cap on the suction pipe to prevent oil spillage and moisture entry.
5. Install plugs into the compressor suction and the discharge port to prevent loss of oil during removal.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

6. Raise the vehicle.
7. Remove the lower cradle splash shield to cradle and wheelhouse fasteners and remove the splash shield.
8. Remove the discharge line to compressor bolt.
9. Remove the discharge line and the seal washer from the compressor.
10. Install a cap on the discharge line to prevent oil spillage and moisture entry.
11. Using a 3/8 in ratchet, rotate the belt tensioner counter clockwise and remove the belt from the compressor pulley.
12. Disconnect the compressor clutch electrical connector.
13. Remove the compressor-to-engine bolts and remove the compressor.

### Installation Procedure

Notice: Compressor oil must be balanced before installation. Failure to balance compressor oil may result in reduced A/C performance and higher system pressure.

1. Install caps on the compressor suction and discharge ports to prevent oil spillage during installation.
2. Install the compressor to the engine block.
3. Hand start the rear and bottom compressor to engine block bolts.
4. Install the upper bolt and hand start.
5. Torque all bolts.

Tighten
Tighten the compressor-to-engine block bolts to 22 N·m (17 lb ft).

Important:

• | Do not lubricate seal washers.

• | Always install new seal washers to prevent refrigerant leaks.

6. Remove the cap from the discharge line and install a new seal washer.
7. Install the discharge line to the compressor and hand start the bolt.

Tighten
Tighten the discharge line-to-compressor bolt to 16 N·m (12 lb ft).

8. Using a 3/8 in ratchet, rotate the belt tensioner counter clockwise and install the belt on the compressor pulley.
9. Connect the compressor clutch electrical connector.
10. Install the lower cradle splash shield by sliding the shield (1) between the wheelhouse liner (2) and the wheelhouse (3). Install the splash shield to wheelhouse and cradle fasteners.

Tighten
Tighten the splash shield-to-wheelhouse and cradle fasteners to 5 N·m (44 lb in).

Important:

• | Do not lubricate the seal washers.

• | Always install new seal washers.

11. Remove the cap from the suction pipe and install a new seal washer.
12. Lower the vehicle.
13. Install the suction pipe to the compressor and hand start the bolt.

Tighten
Tighten the suction pipe-to-compressor bolt to 16 N·m (12 lb ft).

14. Connect the negative battery cable.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

15. Evacuate, charge, and leak check the A/C system.
16. Run the A/C performance test.

## Air Conditioning Compressor Replacement L81

### Removal Procedure

1. Disconnect the negative battery cable.

Important: Verifying the purity of the refrigerant with a purity identifier before recovery is recommended.

2. Recover the refrigerant using an approved refrigerant recovery system. Measure the amount of oil lost during recovery and record the amount.

Caution: Refer to HVAC Compressor Lines/Hoses Caution in the Preface section.

3. Remove the accessory drive belt from the tensioner pulley by rotating the belt tensioner counter-clockwise.

Notice: When servicing the compressor, keep dirt and foreign material from getting on or into the compressor parts and system. Clean tools and clean work area are important for proper service. The compressor connections and the outside of the compressor should be cleaned before any ON CAR repairs, or before removal of the compressor. The parts must be kept clean at all times and any parts to be assembled should be cleaned with a non-petroleum based solvent and dried with air. Use only lint free cloths to wipe parts. Do not allow solvent to enter compressor or hoses.

4. Remove the suction pipe-to-compressor bolt.
5. Remove the suction pipe and the seal washer from the compressor.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

6. Raise the vehicle.
7. Remove the lower cradle splash shield to cradle and wheelhouse fasteners and remove the splash shield.
8. Disconnect the compressor clutch electrical connector.
9. Remove the discharge line to compressor bolt.
10. Remove the discharge line and seal washer from the compressor.
11. Install a cap on the discharge hose to prevent oil spillage and moisture entry.
12. Install a cap on the suction pipe to prevent oil spillage and moisture entry.
13. Install caps on the compressor suction and discharge ports to prevent loss of oil during removal.
14. Remove the 3 compressor-to-engine bolts.
15. Remove the compressor.

### Installation Procedure

Notice: Compressor oil must be balanced before installation. Failure to balance compressor oil may result in reduced A/C performance and higher system pressure.

1. Install caps onto the compressor suction and discharge ports to prevent oil spillage during installation.
2. Install the compressor to engine block.
3. Hand start the rear and bottom compressor to engine block bolts.
4. Install the upper bolt through the wiring harness bracket and then hand start.

Important: Ensure wiring harness bracket does not rotate as the upper bolt is tightened.

5. Torque all bolts.

Tighten
Tighten the compressor-to-engine block bolts to 20 N·m (15 lb ft).

Important:

• | Do not lubricate the seal washers.

• | Always install new seal washers to prevent refrigerant leaks.

6. Remove the cap from the suction pipe and install a new seal washer.
7. Install the suction pipe to the compressor and hand start the bolt.
8. Remove the cap from the discharge line and install a new seal washer.
9. Install the discharge line to the compressor and hand start.

Tighten
Tighten the discharge line-to-compressor bolt to 16 N·m (12 lb ft).

10. Connect the compressor clutch electrical connector.
11. Position the accessory drive belt on the compressor clutch pulley.
12. Install the lower cradle splash shield by sliding the shield (1) between the wheelhouse liner (2) and the wheelhouse (3). Install the splash shield to wheelhouse and cradle fasteners.

Tighten
Tighten the splash shield-to-wheelhouse and cradle fasteners to 5 N·m (44 lb in).

13. Lower the vehicle.
14. Tighten the suction pipe-to-compressor bolt.

Tighten
Tighten the suction pipe-to-compressor bolt to 16 N·m (12 lb ft).

15. Rotate the belt tensioner counter clockwise and install the accessory drive belt.
16. Connect the negative battery cable.

Tighten
Tighten the battery terminal bolts to 16 N·m (12 lb ft).

17. Evacuate, charge, and leak check the A/C system.
18. Run the A/C performance test.