Installation (2.2L)

WARNING: This page is about a different car, the 2002 Saturn LW300, 2002 Saturn LW200, 2002 Saturn L300, 2002 Saturn L200, and 2002 Saturn L100. However, it is still accessible from the selected car via links, so may be relevant.

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

NOTE: PAG oil charge can be identified by locating the label on the rear of the A/C compressor. The 65cc PAG oil charged service replacement A/C compressor will read 65cc COMP/150cc SYS (150cc oil charge in the total system for the model year serviced). Improper quantity of oil charge in the system will degrade the performance. See Fig 7 .

If installing a NEW compressor, place A/C compressor on a clean work bench with high and low side ports in an upright position. With A/C compressor high and low side ports in an upright position, slowly remove the high side cap retaining bolt to release nitrogen (N2) charge. Remove high and low side caps. Install the high and low side caps on the A/C compressor removed from the vehicle, to prevent any oil from leaking out when the A/C compressor is being shipped.

NOTE: Oil drained from NEW A/C compressor can be installed if drained into a clean, dry container. Additional NEW Saturn PAG oil may be needed to obtain the amount of PAG oil required.

Install oil drain adapters on high and low side ports of NEW A/C compressor. Drain oil from NEW A/C compressor into a clean, dry container. See Fig 6 .
- Position A/C compressor to drain oil from high side port first.
- Move A/C compressor to different positions to remove all the oil possible.
- Turn A/C compressor over to drain oil from low side port.
- Rotate A/C compressor drive plate in both directions to remove oil from the A/C compressor chambers.
- Stop oil draining when the oil coming from the low and high side ports becomes only drops.
Measure and record oil removed from A/C compressor. Add recorded amount of oil drained from removed A/C compressor plus amount of oil lost during the recovery process to the NEW A/C compressor. Install caps on compressor suction and discharge ports to prevent oil spillage during installation.
Install compressor to engine block by starting rear and bottom compressor-to-engine block bolts. Do not tighten at this time. Then install the top compressor-to-engine block bolt. See Fig 5 . Tighten all bolts to specification. See TORQUE SPECIFICATIONS .

NOTE: Do not lubricate NEW seal washers.

Remove cap or tape from discharge hose and install a NEW seal washer. Install discharge hose to compressor. See Fig 3 . Tighten to specification. See TORQUE SPECIFICATIONS . Install clutch electrical connector. Using a 3/8 in ratchet, rotate belt tensioner counter clockwise and install belt on compressor pulley. See Fig 4 .
Install lower cradle splash shield by sliding the shield between wheelhouse liner and wheelhouse. See Fig 2 . Install splash shield to wheelhouse and cradle fasteners. Tighten to specification and lower vehicle.
Remove cap or tape from suction hose and install a NEW seal washer. Install suction hose to compressor. See Fig 1 . Tighten to specification. See TORQUE SPECIFICATIONS .
Connect negative battery cable. Evacuate and recharge A/C system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Ensure A/C system is operating properly. See A/C SYSTEM PERFORMANCE under PERFORMANCE TESTS.