Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Saturn ION L4-2.2L VIN FFACTORY OEM SERVICE PROCEDURE
Compressor Replacement
COMPRESSOR REPLACEMENT
TOOLS REQUIRED
- J 39400-A Halogen Leak Detector
- J 44811 Accessory Belt Tensioner Unloader
REMOVAL PROCEDURE
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Raise and support the vehicle. Refer to Vehicle Lifting.
3. Remove the front fender liner.
4. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
5. Remove the drive belt.
6. Disconnect the electrical connector from the compressor.
7. Remove the compressor and condenser hose assembly bolt from the compressor.
8. Remove the compressor and condenser hose assembly from the compressor.
9. Remove and discard the sealing washers.
10. Remove the compressor mounting bolts.
11. Remove the compressor.
INSTALLATION PROCEDURE
1. If you are replacing the compressor, refer to Compressor Oil Balancing.
NOTE: 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.
IMPORTANT: 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.
2. Install the compressor and the bolts to the engine.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the bolts to 22 N.m (16 lb ft).
3. Install new sealing washers on the hose fittings.
4. Install the hose assembly to the compressor.
5. Install the assembly bolt.
Tighten
Tighten the bolt to 20 N.m (15 lb ft).
6. Connect the compressor electrical connector.
7. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
8. Install the drive belt.
9. Install the front fender liner.
10. Lower the vehicle.
11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
12. Leak test the fittings using J 39400-A.
TOOLS REQUIRED
- J 39400-A Halogen Leak Detector
- J 44811 Accessory Belt Tensioner Unloader
REMOVAL PROCEDURE
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Raise and support the vehicle. Refer to Vehicle Lifting.
3. Remove the front fender liner.
4. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
5. Remove the drive belt.
6. Disconnect the electrical connector from the compressor.
7. Remove the compressor and condenser hose assembly bolt from the compressor.
8. Remove the compressor and condenser hose assembly from the compressor.
9. Remove and discard the sealing washers.
10. Remove the compressor mounting bolts.
11. Remove the compressor.
INSTALLATION PROCEDURE
1. If you are replacing the compressor, refer to Compressor Oil Balancing.
NOTE: 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.
IMPORTANT: 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.
2. Install the compressor and the bolts to the engine.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the bolts to 22 N.m (16 lb ft).
3. Install new sealing washers on the hose fittings.
4. Install the hose assembly to the compressor.
5. Install the assembly bolt.
Tighten
Tighten the bolt to 20 N.m (15 lb ft).
6. Connect the compressor electrical connector.
7. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
8. Install the drive belt.
9. Install the front fender liner.
10. Lower the vehicle.
11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
12. Leak test the fittings using J 39400-A.
Factory Service Tools
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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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.