A/C Compressor Replacement

REMOVAL

WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION.

1. Recover the refrigerant from the refrigerant system.
2. Disconnect and isolate the battery negative cable.
3. Remove the nut that secures the suction line fitting to the top of the compressor.
4. Disconnect the suction line fitting from the compressor suction port.
5. Remove the O-ring seal and gasket from the suction line fitting and discard.
6. Install plugs in, or tape over the opened suction line fitting and the compressor suction port.
7. Remove the nut that secures the discharge line fitting to the top of the compressor.
8. Disconnect the discharge line fitting from the compressor discharge port.
9. Remove the O-ring seal and gasket from the discharge line fitting and discard.
10. Install plugs in, or tape over the opened discharge line fitting and the compressor discharge port.
11. Raise and support the vehicle.
12. Remove the serpentine accessory drive belt from the front of the engine.

A/c Compressor - 2.4L Shown. 2.5L Typical:

A/c Compressor - 3.3L/3.8L Engine:

13. Disconnect the engine wire harness connector from the compressor clutch coil pigtail wire connector on the top of the compressor.
14. On models with the 3.3L and 3.8L engines, disengage the retainer on the engine wire harness compressor clutch coil take out from the bracket on the top of the compressor.
15. On models with the 3.3L and 3.8L engines, remove the two bolts and two nuts that secure the compressor to the engine.
16. On models with the 2.4L and 2.5L engine, remove the four bolts that secure the compressor to the mounting bracket on the engine (2.4L), or the cylinder block (2.5L).
17. Remove the A/C 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.

NOTE: The filter/drier should always be replaced when the compressor is replaced. This will remove any contaminants including moisture from the system.

INSTALLATION

NOTE: If a replacement A/C compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle.

NOTE: The filter/drier should always be replaced when the compressor is replaced. This will remove any contaminants including moisture from the system.

1. Position the A/C compressor into the engine compartment.
2. On models with the 2.4L and 2.5L engine, loosely install the four bolts that secure the compressor to the mounting bracket on the engine (2.4L), or the cylinder block (2.5L). Tighten the bolts to 28 Nm (21 ft. lbs.).
3. On models with the 3.3L and 3.8L engines, loosely install the two bolts and two nuts that secure the compressor to the engine. Tighten each of the fasteners using the following sequence to 54 Nm (40 ft. lbs.).
- The upper nut at the front of the compressor.
- The lower nut at the front of the compressor.
- The upper bolt at the rear of the compressor.
- The lower bolt at the rear of the compressor.

4. On models with the 3.3L and 3.8L engines, engage the retainer on the engine wire harness compressor clutch coil take out to the bracket on the top of the compressor.
5. Connect the engine wire harness connector to the compressor clutch coil pigtail wire connector on the top of the compressor.
6. Reinstall the serpentine accessory drive belt.
7. Lower the vehicle.
8. Remove the tape or plugs from the compressor discharge port and the discharge line fitting.
9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting.
10. Install a new gasket and reconnect the discharge line fitting to the compressor discharge port.
11. Install the nut that secures the discharge line fitting to the compressor. Tighten the nut to 23 Nm (17 ft. lbs.).
12. Remove the tape or plugs from the compressor suction port and the suction line fitting.
13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting.
14. Install a new gasket and reconnect the suction line fitting to the compressor suction port.
15. Install the nut that secures the suction line fitting to the compressor. Tighten the nut to 23 Nm (17 ft. lbs.).
16. Reconnect the battery negative cable.
17. Evacuate the refrigerant system.
18. Charge the refrigerant system.