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HOMESERVICE MANUALSCHEVROLET2000CAVALIER BASE, 4D SEDAN, 2.4 TREPAIR AND DIAGNOSIS (SINGLE PAGE)HEATING, VENTILATION & A/C (HVAC)GENERAL SERVICINGHVAC SYSTEM - COMPRESSOR SERVICINGZEXEL ROTARY VANECLUTCH ASSEMBLYREMOVAL (SATURN)
2000 Chevrolet Cavalier Base, 4D Sedan, 2.4 T

Removal (Saturn)

2000 Chevrolet Cavalier Base, 4D Sedan, 2.4 TSECTION Removal (Saturn)
  1. On "L" models, disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Loosen tensioner and remove drive belt from pulley. Disconnect clutch electrical connector. Disconnect refrigerant lines and install plugs to lines and compressor. Remove compressor.
  2. On "S" models, loosen tensioner and remove drive belt from pulley. Disconnect clutch electrical connector. If equipped with secondary Air Pump Reaction (AIR) system, remove combination valve mounting nuts. Disconnect air hose, vacuum source hose and move combination valve aside. Remove air pipe.
    3. NOTE: When moving compressor, ensure discharge line does not change position and/or loosen at condenser connection. An A/C system leak could result.
  3. Remove compressor mounting bolts. With refrigerant lines connected lift compressor upward and forward. Install one front mounting bolt through front engine bracket top hole and bottom rear compressor mounting ear. Tighten bolt so compressor is supported by mounting bracket.
  4. On all models, position a screwdriver between 2 clutch face vibration dampeners to hold drive plate, and remove clutch drive plate center bolt. Using a flat-blade screwdriver pry evenly under drive plate, and remove drive plate and shims.
  5. Remove pulley external snap ring. Position Puller Center Adapter (SA9149AC-2) over end of compressor shaft. Attach 3-jaw puller to back of pulley. Tighten puller bolt against pulley center adapter and remove pulley. Remove clutch coil screws. Lightly tapping end of screwdriver with a plastic hammer will loosen screws for easier removal. Disconnect clutch coil wire and remove clutch coil.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.