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Air Conditioning Compressor Replacement (HP5)

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Air Conditioning Compressor
GM2141912Courtesy of GENERAL MOTORS CORP.
Callout Component Name
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure will perform the following tasks:
  • Identify how to disable high voltage.
  • Identify how to test for the presence of high voltage.
  • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Failure to follow the procedures exactly as written may result in serious injury or death.
CAUTION: This A/C system's high voltage A/C Compressor uses Polyolester (POE) refrigerant oil instead of Polyalkylene Glycol (PAG) refrigerant oil. Use only approved GM POE oil no more than two hours after removal from its sealed moisture proof packaging (reference GM POE label for proper usage) in refrigerant systems equipped with a High Voltage A/C compressor. GM POE oil is intended to be used with the J-45037 A/C oil injector and the GE-48997 A/C POE oil injector hose. Use of any refrigerant oil other than the approved GM POE, handled and installed per GM's requirements may result in compressor failure and/or loss of HV isolation with associated DTC's set.

Preliminary Procedures

  1. Disable hybrid high voltage system. Refer to High Voltage Disabling and High Voltage Enabling .
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (LY7) or Fuel Injector Sight Shield Replacement (LCS) .
  3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (With HP5)  or Refrigerant Recovery and Recharging (Without HP5) .
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Remove the suction hose from the A/C compressor. Refer to Suction Hose Replacement (HP5) .
  6. Remove the discharge hose from the A/C compressor. Refer to Discharge Hose Replacement (HP5) .
    NOTE: Ensure to cap all HVAC line connections immediately after removal to avoid contamination. Refer to Handling of Refrigerant Lines and Fittings .
  7. Remove the generator control module cover to access the A/C compressor cable connector bolts.
  8. Remove A/C compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement .
1 A/C Compressor Cable Bolt (Qty: 2)
CAUTION: High Voltage (HV) cables should never be removed from the mounting block. Removal of the individual HV cable from the mounting block may result in HV cable and/or component damage from improper:
  • Cable sealing
  • Electrical shielding
  • Terminal position assurance
CAUTION: Refer to Fastener Caution .

Tighten:  9 N.m (80 lb in)
2 Battery Positive and Negative Cable Mounting Bolt (Qty: 2)

Tighten:  9 N.m (80 lb in)
3 Battery Cable and A/C Compressor Cable Guide Assembly
4 A/C Compressor Cable Bolt (Qty: 2)

Tighten:  9 N.m (80 lb in)
5 A/C Compressor Cable

Procedure

  1. Pull A/C compressor cable straight outward from module and discard seal.
  2. Remove any fasteners from A/C compressor cable brackets.
6 A/C Compressor Bolt (Qty: 4)

Procedure

  1. Relocate and support the A/C compressor forward while removing the A/C compressor bracket.
  2. Mandatory torque sequence required per illustration.

Tighten:  50 N.m (37 lb ft)
7 A/C Compressor

Procedure

  1. Disconnect three wire low voltage electrical connector from compressor.
  2. The A/C compressor cable is part of the compressor and is serviced as an assembly.
  3. Insert bottom compressor bolts into compressor before installing compressor to vehicle.
  4. Use only GM approved Polyolester (POE) oil. Failure to use the approved GM POE oil per GM's handling and installation requirements may result in compressor failure and/or loss of High Voltage isolation with the associated DTC's set.
  5. When replacing the A/C compressor, balance the compressor oil. Refer to Air Conditioning Compressor Oil Balancing (With HP5)  or Air Conditioning Compressor Oil Balancing (Without HP5) 
  6. Using J 39400:  Electronic Halogen Leak Detector, leak test A/C compressor fittings.

Special Tools: 
J 39400:  Electronic Halogen Leak Detector
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