How to replace compressor on Chevy Cobalt?

COMPRESSOR.

Removal & Installation

2.0L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Discharge the refrigerant. Refer to Heating & Air Conditioning, discharging the system.
3. Raise and safely support the vehicle.
   
   
   

   

   Fig. Remove the right front fender liner
4. Remove the right side tire and wheel assembly.
5. Remove the 7 front right side wheelhouse liner screws (1).
6. Remove the 10 right front wheelhouse liner retainers (2) using a flat-bladed tool.
7. Remove or disconnect the following:
   
   
   The accessory drive belt. Refer to Accessory Drive Belts, removal and installation

   The electrical connector from the compressor
   
   

   

   

   Fig. Remove the compressor and condenser hose assembly bolt from the compressor

   The compressor and condenser hose assembly bolt from the compressor

   The compressor and condenser hose assembly from the compressor

   Remove and discard the sealing washers
   
   

   

   

   Fig. Remove the auxiliary intercooler pump bolts and position the pump toward the driver-s side of the vehicle

   The auxiliary intercooler pump bolts and position the pump toward the driver-s side of the vehicle

   The compressor mounting bolts

   The compressor
   
   

   

   

   Fig. Remove the compressor mounting bolts and the A/C compressor

To install:

WARNING

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, use the following procedure:
   1. Drain and measure as much of the refrigerant oil as possible from the removed compressor.
   2. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
      
      
      

      

      Fig. Drain the oil from both the suction and discharge ports of the removed compressor
   3. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
   4. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
   5. Properly discard the used refrigerant oil.
      
      WARNING

      The refrigerant oil in the A/C system must be balanced during compressor replacement.
      
      
      
      NOTE

      The replacement compressor is shipped with 2.5 oz (74 ml) of refrigerant oil.
      
      
      
      
      

      

      Fig. Balancing the refrigerant oil in the A/C system by adding PAG oil to the A/C compressor
   6. Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor. If the amount of refrigerant oil drained and recorded from the removed compressor is:
      
      
      Less than 2.5 oz (74 ml), leave the 2.5 oz (74 ml) in the replacement compressor

      More than 2.5 oz (74 ml), add to the compressor the difference between the 2.5 oz (74 ml) and the amount drained
2. Install or connect the following:
   
   
   The compressor and the bolts to the engine. Tighten the bolts to 18 ft. lbs. (25 Nm)

   New sealing washers on the hose fittings

   The hose assembly to the compressor

   The assembly bolt. Tighten the bolt to 15 ft. lbs. (20 Nm)

   The compressor electrical connector

   The auxiliary intercooler pump. Tighten the pump bolt to 88 inch lbs. (10 Nm)

   The accessory drive belt. Refer to Accessory Drive Belts, removal and installation

   The front fender liner with the 7 liner screws tightened to 18 inch lbs. (2 Nm) and the 10 liner retainers placed into position
3. Lower the vehicle.
4. Evacuate and charge the refrigerant system. Refer to Heating & Air Conditioning, evacuating the system and charging the system.
5. Leak test the fittings. Refer to Heating & Air Conditioning, leak testing.

2.2L & 2.4L Engines

First Design

1. Before servicing the vehicle, refer to the Precautions Section.
2. Discharge the refrigerant. Refer to Heating & Air Conditioning, discharging the system.
3. Raise and safely support the vehicle.
   
   
   

   

   Fig. Remove the right front fender liner
4. Remove the right side tire and wheel assembly.
5. Remove the 7 front right side wheelhouse liner screws (1).
6. Remove the 10 right front wheelhouse liner retainers (2) using a flat-bladed tool.
7. Remove or disconnect the following:
   
   
   The accessory drive belt. Refer to Accessory Drive Belts, removal and installation

   The electrical connector from the compressor
   
   

   

   

   Fig. Remove the compressor and condenser hose assembly bolt from the compressor

   The compressor and condenser hose assembly bolt from the compressor

   The compressor and condenser hose assembly from the compressor

   Remove and discard the sealing washers

   The compressor mounting bolts

   The compressor
   
   

   

   

   Fig. Remove the compressor mounting bolts and the A/C compressor

To install:

WARNING

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, use the following procedure:
   1. Drain and measure as much of the refrigerant oil as possible from the removed compressor.
   2. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
      
      
      

      

      Fig. Drain the oil from both the suction and discharge ports of the removed compressor
   3. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
   4. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
   5. Properly discard the used refrigerant oil.
      
      WARNING

      The refrigerant oil in the A/C system must be balanced during compressor replacement.
      
      
      
      NOTE

      The replacement compressor is shipped with 2.5 oz (74 ml) of refrigerant oil.
      
      
      
      
      

      

      Fig. Balancing the refrigerant oil in the A/C system by adding PAG oil to the A/C compressor
   6. Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor. If the amount of refrigerant oil drained and recorded from the removed compressor is:
      
      
      Less than 2.5 oz (74 ml), leave the 2.5 oz (74 ml) in the replacement compressor

      More than 2.5 oz (74 ml), add to the compressor the difference between the 2.5 oz (74 ml) and the amount drained
2. Install or connect the following:
   
   
   The compressor and the bolts to the engine. Tighten the bolts to 18 ft. lbs. (25 Nm)

   New sealing washers on the hose fittings

   The hose assembly to the compressor

   The assembly bolt. Tighten the bolt to 15 ft. lbs. (20 Nm)

   The compressor electrical connector

   The accessory drive belt. Refer to Accessory Drive Belts, removal and installation

   The front fender liner with the 7 liner screws tightened to 18 inch lbs. (2 Nm) and the 10 liner retainers placed into position
3. Lower the vehicle.
4. Evacuate and charge the refrigerant system. Refer to Heating & Air Conditioning, evacuating the system and charging the system.
5. Leak test the fittings. Refer to Heating & Air Conditioning, leak testing.

Second Design

1. Before servicing the vehicle, refer to the Precautions Section.
2. Discharge the refrigerant. Refer to Heating & Air Conditioning, discharging the system.
3. Raise and safely support the vehicle.
   
   
   

   

   Fig. Remove the right side engine splash shield: the splash shield push-in retainers (1) and the splash shield (2)
4. Remove the right side engine splash shield:
   1. Remove the right side tire and wheel assembly.
   2. Remove all splash shield push-in retainers (1) except the one hidden by the inner fender.
   3. Remove the front 3 inner fasteners and reposition to access the hidden fastener for removal.
5. Remove or disconnect the following:
   
   
   The accessory drive belt. Refer to Accessory Drive Belts, removal and installation

   The electrical connector from the compressor
   
   

   

   

   Fig. Remove the compressor and condenser hose assembly bolt from the compressor

   The compressor and condenser hose assembly bolt from the compressor

   The compressor and condenser hose assembly from the compressor

   Remove and discard the sealing washers

   The compressor mounting bolts

   The compressor
   
   

   

   

   Fig. Remove the compressor mounting bolts and the A/C compressor

To install:

WARNING

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.

WARNING

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, use the following procedure:
   1. Drain and measure as much of the refrigerant oil as possible from the removed compressor.
   2. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
      
      
      

      

      Fig. Drain the oil from both the suction and discharge ports of the removed compressor
   3. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
   4. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
   5. Properly discard the used refrigerant oil.
      
      WARNING

      The refrigerant oil in the A/C system must be balanced during compressor replacement.
      
      
      
      NOTE

      The replacement compressor is shipped with 2.5 oz (74 ml) of refrigerant oil.
      
      
      
      
      

      

      Fig. Balancing the refrigerant oil in the A/C system by adding PAG oil to the A/C compressor
   6. Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor. If the amount of refrigerant oil drained and recorded from the removed compressor is:
      
      
      Less than 2.5 oz (74 ml), leave the 2.5 oz (74 ml) in the replacement compressor

      More than 2.5 oz (74 ml), add to the compressor the difference between the 2.5 oz (74 ml) and the amount drained
2. Install or connect the following:
   
   
   The compressor and the bolts to the engine. Tighten the bolts to 16 ft. lbs. (22 Nm)

   New sealing washers on the hose fittings

   The hose assembly to the compressor

   The assembly bolt. Tighten the bolt to 15 ft. lbs. (20 Nm)

   The compressor electrical connector

   The accessory drive belt. Refer to Accessory Drive Belts, removal and installation
3. Install the right side engine splash shield:
   1. Install the hidden fastener and then install the 3 inner fasteners.
   2. Install all splash shield push-in retainers.
   3. Install the right side tire and wheel assembly. Tighten lug nuts to 100 ft. lbs (140 Nm).
4. Lower the vehicle.
5. Evacuate and charge the refrigerant system. Refer to Heating & Air Conditioning, evacuating the system and charging the system.
6. Leak test the fittings. Refer to Heating & Air Conditioning, leak testing.

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