Here's a general outline of the process. Specific steps and torque specifications may vary slightly depending on the exact engine and AC system configuration of your Cavalier. Always consult a repair manual specific to your vehicle's year, make, and model for detailed instructions and diagrams. A Haynes or Chilton manual is a good investment.
1. Safety First:
* Wear safety glasses: Pressure can build up during the process.
* Work in a well-ventilated area: AC refrigerant is harmful if inhaled.
* Recover the refrigerant: This is CRUCIAL. You MUST use an AC recovery machine to capture the refrigerant before disconnecting any lines. This is usually done by a professional, but you can rent a recovery machine from some auto parts stores. Discharging refrigerant into the atmosphere is illegal and harmful to the environment.
2. Preparation:
* Disconnect the battery's negative terminal. This prevents accidental short circuits.
* Locate the AC compressor: It's usually located on the engine's front, driven by a belt.
* Identify all components: Pay close attention to the hoses, electrical connections, and mounting bolts. Take pictures before disconnecting anything.
* Gather your tools: You'll need wrenches (metric), sockets, a ratchet, a compressor clutch pulley tool (to hold the pulley while you remove the compressor mounting bolts), possibly a torque wrench, and potentially a serpentine belt tensioner tool.
3. Removal:
* Release the serpentine belt tension: The method for this varies depending on your engine. Some have automatic tensioners, while others require a tool to manually release the tension. Consult your repair manual.
* Disconnect the electrical connector: This is usually a single connector to the compressor clutch.
* Disconnect the high and low pressure AC lines: You may need AC line wrenches to avoid damaging the fittings. Remember, the refrigerant *must* be evacuated first!
* Remove the compressor mounting bolts: The compressor is usually mounted to the engine block. Use the clutch pulley tool to hold the pulley while you remove these bolts.
* Remove the compressor: Once the bolts are removed, carefully remove the compressor.
4. Installation:
* Install the new compressor: This is the reverse of the removal process. Ensure the new compressor is properly seated and aligned.
* Connect the high and low pressure AC lines: Tighten the fittings to the proper torque specification (check your repair manual).
* Reconnect the electrical connector.
* Reinstall the serpentine belt. Ensure the belt is properly routed and tensioned.
* Reconnect the battery's negative terminal.
5. Evacuation and Recharge:
* This is the most crucial step and should be done by a professional AC technician. The system must be completely evacuated of air and moisture, then recharged with the correct amount and type of refrigerant. Improperly charging the system can lead to compressor failure and other damage.
Disclaimer: This is a simplified overview. Attempting this repair without proper knowledge and tools can damage your vehicle or cause injury. If you're not comfortable with automotive repair, it's best to take your Cavalier to a qualified mechanic specializing in AC repair. They have the tools and experience to perform the job safely and correctly.
