Safety Warning
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HOMESERVICE MANUALSCHEVROLET2003MONTE CARLO V6-3.8L VIN KREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCOMPRESSOR HVACSERVICE AND REPAIRCOMPRESSOR REPLACEMENT
2003 Chevrolet Monte Carlo V6-3.8L VIN K
Compressor Replacement
2003 Chevrolet Monte Carlo V6-3.8L VIN KSECTION Compressor Replacement
TOOLS REQUIRED
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Recover the refrigerant.
2. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
3. Remove the drive belt from the A/C compressor pulley and position the drive belt aside.
4. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
5. Raise and support the vehicle. Refer to Vehicle Lifting.
6. Remove the splash shield from the right side of the engine.
7. Remove the lower air deflector.
8. Remove the A/C compressor hose bolt.
9. Disconnect the A/C compressor hose from A/C compressor.
10. Disconnect the electrical connector from the A/C compressor.
11. Remove and discard the sealing washers.
12. Remove the rear mounting bracket from the A/C compressor.
13. Remove the A/C compressor mounting nuts.
14. Remove the A/C compressor.
15. If replacing the compressor, balance the compressor oil.
IMPORTANT: Replacement compressors are shipped without PAG oil
INSTALLATION PROCEDURE
1. Install the compressor drain plug (1).
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the drain plug to 20 N.m (15 lb ft).
2. Install the A/C compressor to the vehicle.
3. Install the A/C compressor front nuts.
Tighten
Tighten the nuts to 100 N.m (74 lb ft).
4. Install the rear A/C compressor bolts.
Tighten
Tighten the bolts to 31 N.m (23 lb ft).
5. Install the new sealing washers.
6. Install the A/C compressor hose assembly to the A/C compressor.
7. Install the A/C compressor hose nut to the compressor.
Tighten
Tighten the nut to 33 N.m (24 lb ft).
8. Connect the electrical connector to the A/C compressor.
9. Install the lower air deflector.
10. Install the splash shield to the right side of the engine.
11. Lower the vehicle.
12. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
13. Install the drive belt around the A/C compressor pulley.
IMPORTANT: Make sure the drive belt is aligned into the proper grooves of all pulleys.
14. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
15. Evacuate and recharge the A/C system.
16. Using J 39400-A , leak test the fittings of the component.
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Recover the refrigerant.
2. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
3. Remove the drive belt from the A/C compressor pulley and position the drive belt aside.
4. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
5. Raise and support the vehicle. Refer to Vehicle Lifting.
6. Remove the splash shield from the right side of the engine.
7. Remove the lower air deflector.
8. Remove the A/C compressor hose bolt.
9. Disconnect the A/C compressor hose from A/C compressor.
10. Disconnect the electrical connector from the A/C compressor.
11. Remove and discard the sealing washers.
12. Remove the rear mounting bracket from the A/C compressor.
13. Remove the A/C compressor mounting nuts.
14. Remove the A/C compressor.
15. If replacing the compressor, balance the compressor oil.
IMPORTANT: Replacement compressors are shipped without PAG oil
INSTALLATION PROCEDURE
1. Install the compressor drain plug (1).
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the drain plug to 20 N.m (15 lb ft).
2. Install the A/C compressor to the vehicle.
3. Install the A/C compressor front nuts.
Tighten
Tighten the nuts to 100 N.m (74 lb ft).
4. Install the rear A/C compressor bolts.
Tighten
Tighten the bolts to 31 N.m (23 lb ft).
5. Install the new sealing washers.
6. Install the A/C compressor hose assembly to the A/C compressor.
7. Install the A/C compressor hose nut to the compressor.
Tighten
Tighten the nut to 33 N.m (24 lb ft).
8. Connect the electrical connector to the A/C compressor.
9. Install the lower air deflector.
10. Install the splash shield to the right side of the engine.
11. Lower the vehicle.
12. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
13. Install the drive belt around the A/C compressor pulley.
IMPORTANT: Make sure the drive belt is aligned into the proper grooves of all pulleys.
14. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
15. Evacuate and recharge the A/C system.
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.