Compressor HVAC: Service and Repair

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.

REMOVAL
1. Disconnect the negative battery cable.
2. Recover the refrigerant from the refrigerant system.

2.7L Diesel Compressor - RHD (LHD Typical):

3. Remove the accessory drive belt from the compressor clutch.
4. Remove the bolt that secures the suction line fitting to the top of the compressor.
5. Disconnect the suction line fitting from the compressor suction port.
6. Remove the seal from the suction line fitting and discard.
7. Install plugs in, or tape over the opened suction line fitting and the compressor suction port.
8. Remove the bolt that secures the discharge line fitting to the top of the compressor.
9. Disconnect the discharge line fitting from the compressor discharge port.
10. Remove the seal from the discharge line fitting and discard.
11. Install plugs in, or tape over the opened discharge line fitting and the compressor discharge port.
12. Disconnect the engine wire harness connector for the compressor clutch coil from the coil pigtail wire connector on the top of the compressor.
13. Raise the vehicle on a hoist.
14. Support the compressor and remove the three compressor mounting bolts.
15. Remove the compressor from the engine compartment.

NOTE: If a replacement compressor is being installed, be certain to drain and measure the refrigerant oil contained in the removed compressor. This will determine how much oil the replacement compressor must contain before it is installed.

INSTALLATION

CAUTION: Check the oil level before installing the new compressor.

Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.

High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.
1. Position the A/C compressor in the engine compartment and loosely install the three compressor retaining bolts. Tighten the bolts using the following sequence to 20 N.m (15 ft. lbs.).
- The upper bolt at the front of the compressor.
- The lower bolt at the front of the compressor.
- The bolt at the rear of the compressor.

2. Lower the vehicle.
3. Connect the wire harness connector to the compressor clutch.
4. Remove plugs or tape from the discharge line fitting and the compressor discharge port.
5. Lubricate a new rubber O-ring seal with clean refrigerant oil and install the seal onto the discharge line fitting.
6. Connect the discharge line fitting to the compressor discharge port.
7. Install the bolt that secures the discharge line fitting to the top of the compressor. Tighten the bolt to 23 N.m (17 ft. lbs.).
8. Remove plugs or tape from the suction line fitting and the compressor suction port.
9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install the seal onto the suction line fitting.
10. Connect the suction line fitting to the compressor suction port.
11. Install the bolt that secures the suction line fitting to the top of the compressor. Tighten the bolt to 23 N.m (17 ft. lbs.).
12. Install the accessory drive belt.
13. Reconnect the negative battery cable.
14. Evacuate the refrigerant system.
15. Charge the refrigerant system.