97 sunfire ac problem

OK. The sunfire developed a bad grinding noise. At first I replaced the belt tensioner but the noise persisted. After taking a closer look I noticed metal shavings flying off the a/c compressor clutch. So I decided to replace the clutch and pulley. After searching all over I realized I couldn't get pullers to take off the assembley so I replaced the whole compressor. Installation went quick and I recharged with 4 oz. of Pag150 oil and 3 12 oz. cans of refrigerant. After all that the clutch never engaged. So I checked all the fuses and even disassembled the relay to find out all was fine. The two terminals at the relay have power yet the clutch isn't getting it.

So I'm thinking maybe I have an open coming from the relay or , from what I've heard on other vehicles, the ambient air is too cold and the computer isn't actually telling it to turn on. Is this a possibility on Sunfires? I'd really rather not tear into the harness unless I have to since it runs under the intake and whatnot.

Any guidance or suggestions would be great. As far as I know, before replacing the compressor it kicked in fine, but im not sure if it did in the middle of winter.


Please help!

First, 4 ounces of refrigerant oil in an evacuated system is too little.

Second, three 12 ounce cans of R134A (36 ounces) might be too much. The system likely requires between 32-40 ounces. If the 4 ounce oil charge also contained 6 ounces of refrigerant, the system may be overcharged. If you used liquid PAG administered via a hose, it might be O.K..

It is possible that the PCM is not enabling the AC, or that the low pressure cutout is not enabling the AC.

Well the system wasn't mechanically evacuated if that is what ur refrring to. I took into consideration the amount I obvserved leak out when the hoses were disconnected although maybe I could use a wee bit more oil. As far as poundage on the refrigerant, the label on the car states it takes 1.5 lbs and I filled it to where my guage reads ok.

Since I have voltage at both inputs on the relay I tried jumping the relay switch with it removed today, which engaged the clutch. When I returned the relay It continued to run. But after checking operation when I got home from work the clutch is not engaging which is maybe making me think my relay is weak and not working properly.

If I am right, if the computer isn't calling the clutch to engage I wouldnt be able to jump it at the relay, correct?

I really appreciate the response. A/C seems to be taboo and no one wants to chime in. lol I also had a friend explain that there might have been some moisture that entered the system and is hanging it up. He suggested a evac and charge at a local shop. But at over $100 I think I'll try the $16 relay first.

At least by getting the clutch to engage today I got some lubrication thru the pump so I'm not too worried about driving it a bit before it's fully functional.

Just an FYI for future reference, It warmed up into the 50's here this week and the ac worked. Therefore there is a temperature cutoff when it gets too cold.