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.
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HOMESERVICE MANUALSCHEVROLET2002MONTE CARLO V6-3.8L VIN KREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCOMPRESSOR HVACSERVICE AND REPAIRCOMPRESSOR REPLACEMENT
2002 Chevrolet Monte Carlo V6-3.8L VIN K
Compressor Replacement
2002 Chevrolet Monte Carlo V6-3.8L VIN KSECTION Compressor Replacement
TOOLS REQUIRED
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the accessory drive belt.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Remove the splash shield from the right side of the engine.
5. Remove the lower air deflector.
6. Remove the A/C compressor hose bolt.
7. Disconnect the A/C compressor hose from A/C compressor.
8. Disconnect the electrical connector from the A/C compressor.
9. Remove and discard the sealing washers.
10. Remove the rear mounting bracket from the A/C compressor.
11. Remove the A/C compressor mounting nuts.
12. Remove the A/C compressor.
13. Remove the bracket with the mounting bolts, if necessary.
14. If replacing the compressor, drain and measure as much of the oil as possible from the removed compressor:
14.1. Drain the oil from both the suction and discharge ports of the removed compressor into a clean container.
14.2. Remove the compressor crankcase oil drain plug (1) and drain the crankcase oil into the same container.
14.3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
14.4. Properly discard the used PAG oil.
INSTALLATION PROCEDURE
IMPORTANT: The replacement compressor is shipped without PAG oil. Refer to Refrigerant System Capacities for compressor oil capacity.
1. Add the proper amount of PAG oil to the compressor crankcase.
2. Install the compressor drain plug.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Tighten the compressor drain plug (1).
Tighten
Tighten the drain plug to 20 N.m (15 lb ft).
4. Install the A/C compressor to the vehicle.
5. Install the A/C compressor front nuts.
Tighten
Tighten the nuts to 100 N.m (74 lb ft).
6. Install the rear A/C compressor bolts.
Tighten
Tighten the bolts to 31 N.m (23 lb ft).
7. Install the new sealing washers.
8. Install the A/C compressor hose assembly to the A/C compressor.
9. Install the A/C compressor hose nut to the compressor.
Tighten
Tighten the nut to 33 N.m (24 lb ft).
10. Connect the electrical connector to the A/C compressor.
11. Install the lower air deflector.
12. Install the splash shield to the right side of the engine.
13. Lower the vehicle.
14. Install the accessory drive belt.
15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
16. Using J 39400-A, leak test the fittings of the component.
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the accessory drive belt.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Remove the splash shield from the right side of the engine.
5. Remove the lower air deflector.
6. Remove the A/C compressor hose bolt.
7. Disconnect the A/C compressor hose from A/C compressor.
8. Disconnect the electrical connector from the A/C compressor.
9. Remove and discard the sealing washers.
10. Remove the rear mounting bracket from the A/C compressor.
11. Remove the A/C compressor mounting nuts.
12. Remove the A/C compressor.
13. Remove the bracket with the mounting bolts, if necessary.
14. If replacing the compressor, drain and measure as much of the oil as possible from the removed compressor:
14.1. Drain the oil from both the suction and discharge ports of the removed compressor into a clean container.
14.2. Remove the compressor crankcase oil drain plug (1) and drain the crankcase oil into the same container.
14.3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
14.4. Properly discard the used PAG oil.
INSTALLATION PROCEDURE
IMPORTANT: The replacement compressor is shipped without PAG oil. Refer to Refrigerant System Capacities for compressor oil capacity.
1. Add the proper amount of PAG oil to the compressor crankcase.
2. Install the compressor drain plug.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Tighten the compressor drain plug (1).
Tighten
Tighten the drain plug to 20 N.m (15 lb ft).
4. Install the A/C compressor to the vehicle.
5. Install the A/C compressor front nuts.
Tighten
Tighten the nuts to 100 N.m (74 lb ft).
6. Install the rear A/C compressor bolts.
Tighten
Tighten the bolts to 31 N.m (23 lb ft).
7. Install the new sealing washers.
8. Install the A/C compressor hose assembly to the A/C compressor.
9. Install the A/C compressor hose nut to the compressor.
Tighten
Tighten the nut to 33 N.m (24 lb ft).
10. Connect the electrical connector to the A/C compressor.
11. Install the lower air deflector.
12. Install the splash shield to the right side of the engine.
13. Lower the vehicle.
14. Install the accessory drive belt.
15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
16. Using J 39400-A, leak test the fittings of the component.
RENDER: 1.0x
NO RELATED
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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.