Installation

INSTALLATION

CAUTION: If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

CAUTION: The A/C accumulator must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C accumulator can cause serious damage to the replacement A/C compressor.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor.


NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals could result in a refrigerant system leak.




1. If the A/C compressor (6) is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

2. Position the A/C compressor into the engine compartment.

3. Install the four bolts (5) that secure the A/C compressor to the mounting bracket (7). Tighten the bolts to 28 Nm (21 ft. lbs.).

4. Connect the wire harness connectors to the compressor clutch coil connector (1) and the A/C high pressure switch (4).

5. If equipped with diesel engine, install the turbocharger to charge air cooler hose.

6. Lower the vehicle.

7. Remove the tape or plugs from the compressor ports (2 and 3) and the refrigerant line fittings.




8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

9. Connect the A/C discharge line (1) and the A/C suction line (5) to the A/C compressor (3).

10. Install the bolts (4 and 2) that secure the A/C suction and discharge lines to the A/C compressor. Tighten the bolts to 12 Nm (106 in. lbs.).

11. Install the accessory drive belt (7).

12. Reposition the engine cooling module and install the upper radiator support.
13. Connect the upper radiator hose to the radiator. Make sure the retaining clamp is fully secure.
14. Reconnect the negative battery cable.
15. Refill the engine cooling system.
16. Evacuate the refrigerant system.
17. Charge the refrigerant system.