Compressor HVAC: Service and Repair

REMOVAL

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

NOTE: The A/C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch, clutch coil, engine, engine cylinder head or the generator.

1. Recover the refrigerant from the refrigerant system.
2. Disconnect and isolate the battery negative cable.
3. Remove the serpentine drive belt.
4. Disconnect the A/C compressor clutch coil wire harness connector.
5. Depending on engine usage, remove the bolt or nuts that secure the suction and discharge line fittings to the A/C compressor.
6. Disconnect the suction and discharge line fittings from the A/C compressor.
7. Remove the O-ring seals from the suction and discharge line fittings and discard.
8. Install plugs in, or tape over all of the opened refrigerant line fittings and the compressor ports.
9. If equipped with the 5.7L Hemi engine, remove the nuts and bolts that secure the generator and A/C compressor support bracket and remove the bracket from the engine.

A/C Compressor - 3.7L Shown, 4.7L Typical:

A/C Compressor - 5.7L Hemi:

A/C Compressor - 5.9L Diesel:

10. Remove the bolts that secure the A/C compressor to the mounting bracket.
11. Remove the A/C compressor from the engine compartment.

INSTALLATION

NOTE: If a replacement compressor is being installed, be certain to check the refrigerant oil level. See Refrigerant Oil Level for the procedures. Use only refrigerant oil of the type recommended for the compressor in the vehicle.

1. Install the compressor onto the mounting bracket.

A/C Compressor - 3.7L Shown, 4.7L Typical:

2. On the 3.7L and 4.7L engines, install and tighten the bolts in the following sequence:
- Install the inner front bolt #3 and hand tightened.
- Install the outer front bolt #2 and hand tightened.
- Install the rear bolt #1 and hand tightened.
- Tightened the inner front bolt #3 to 40 Nm (30 ft. lbs.).
- Tightened the outer front bolt #2 to 55 Nm (41 ft. lbs.).
- Tightened the rear bolt #1 to 55 Nm (41 ft. lbs.).

A/C Compressor - 5.7L Hemi:

3. For the 5.7L Hemi engine, install and tighten the bolts in the following sequence:
- Install the two long bolts into the mounting bracket and hand tightened.
- Install the rear bolt and hand tightened.
- Tightened the two long bolts to 40 Nm (30 ft. lbs.).
- Tightened the rear bolt to 55 Nm (41 ft. lbs.).

4. For the 5.7L Hemi engine, install the generator and A/C compressor support bracket and retaining nuts and bolts. Tighten the nuts and bolts securely.

A/C Compressor - 5.9L Diesel:

5. For the 5.9L diesel engine, install and tighten the bolts in the following sequence:
- Install the four bolts into the mounting bracket and hand tightened.
- Tightened the four bolts to 24 Nm (17 ft. lbs.).
6. Remove the tape or plugs from the opened refrigerant line fittings and compressor ports.
7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction and discharge 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.
8. Install the suction and discharge line fittings onto the compressor.
9. Install the bolt or nuts (depending on engine application) that secure the suction and discharge line fittings to the compressor. Tighten the bolt or nuts to 28 Nm (20 ft. lbs.).
10. Connect the wire harness connector to the compressor clutch coil.
11. Install the serpentine drive belt.
12. Reconnect the battery negative cable.
13. Evacuate the refrigerant system.
14. Charge the refrigerant system.