Compressor HVAC: Service and Repair

A/C COMPRESSOR

REMOVAL

WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.

1. Recover the refrigerant from the refrigerant system.
2. Disconnect and isolate the negative battery cable.
3. Raise and support the vehicle.
4. On models equipped with the 2.5L and 2.8L diesel engines, remove the belly pan from underneath the engine compartment.
5. Remove the accessory drive belt.
6. Remove the nuts that secure the A/C suction line and the A/C discharge line to the A/C compressor.
7. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-rings seal and gaskets.
8. Install plugs in, or tape over the opened suction and discharge line fittings and the compressor ports.

A/C Compressor 2.4L Shown, 2.5L/2.8L Typical:

9. Disconnect the engine wire harness from the A/C clutch field coil connector. On models with the 3.3L and 3.8L engines, disengage the engine wire harness connector from the bracket located the top of the A/C compressor.
10. On models with the 2.4L, 2.5L and 2.8L engine, remove the four bolts that secure the A/C compressor to the A/C compressor mounting bracket.
11.

A/C Compressor 3.8L Shown, 3.3L Typical:

12. On models with the 3.3L and 3.8L engine, remove the two bolts and two nuts that secure the A/C compressor to the engine.

NOTE:
- If a replacement A/C compressor is being installed, be certain to drain and measure the refrigerant oil contained in the old compressor. This will determine how much refrigerant oil the replacement A/C compressor must contain before it is installed.
- The receiver/drier should always be replaced when the A/C compressor is replaced. This will help remove any contaminants including moisture from the system.

13. Remove the A/C compressor from the engine compartment.

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 A/C compressor in the vehicle.

1. Position the A/C compressor into the engine compartment.
2. On models with the 2.4L, 2.5L and 2.8L engine, loosely install the four bolts that secure the A/C compressor to the A/C compressor mounting bracket. Tighten the bolts to 28 N.m (21 ft. lbs.).
3. On models with the 3.3L and 3.8L engines, loosely install the two bolts and the two nuts that secure the A/C compressor to the engine. Tighten each of the fasteners to 54 N.m (40 ft. lbs.) using the following sequence:
- upper nut at the front of the compressor.
- lower nut at the front of the compressor.
- upper bolt at the rear of the compressor.
- lower bolt at the rear of the compressor.

4. Connect the engine wire harness to the A/C clutch field coil connector. On models equipped with the 3.3L and 3.8L engines, engage the engine wire harness connector to the bracket located at the top of the A/C compressor.
5. Remove the tape or plugs from the suction and discharge line fittings and the compressor ports.
6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and a new gasket onto the A/C suction and discharge line.
7. Connect the A/C suction and discharge lines to the A/C compressor.
8. Install the nut that secures the A/C suction and discharge lines to the A/C compressor. Tighten the nuts to 23 N.m (17 ft. lbs.).
9. Install the accessory drive belt.
10. On models with the 2.5L and 2.8L diesel engine, install the belly pan.
11. Lower the vehicle.
12. Reconnect the negative battery cable.
13. Evacuate the refrigerant system.
14. Charge the refrigerant system.