Compressor HVAC: Service and Repair

AIR CONDITIONING (A/C) COMPRESSOR







Removal and Installation

CAUTION: If installing a new air conditioning compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the air conditioning system.
- If A/C flushing equipment is available, carry out flushing of the air conditioning system prior to installing a new air conditioning compressor.
- If A/C flushing equipment is not available, carry out filtering of the air conditioning system after a new air conditioning compressor has been installed.
- Install a new evaporator core orifice, as directed by the A/C flushing or filtering procedure.
- Install a new suction accumulator as directed by the A/C flushing or filtering procedure.

NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.
- If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If flushing of the air conditioning system has not been carried out, recover the refrigerant.
3. Remove the drive belt from the A/C compressor pulley.

4x4 vehicles
4. Remove the radiator cooling fan and shroud.
5. If equipped, remove the skid plate.

All vehicles
6. Detach the compressor manifold.
1 Loosen the compressor manifold bolt.
2 Detach the compressor manifold bolt.
- To install, tighten to 20 Nm (15 lb-ft).

7. Disconnect the field coil electrical connector.
8. Disconnect the crankshaft position sensor electrical connector and position the wire harness aside.
9. Remove the 3 compressor bolts.
- To install, tighten to 25 Nm (18 lb-ft).

10. Remove the A/C compressor.
11. To install, reverse the removal procedure.
- If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit.
- Install new O-ring seals.
- If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil.

12. If filtering of the refrigerant system is not to be carried out, evacuate, leak test and charge the refrigerant system.