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:
- 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.
- 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.


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

6.0L diesel vehicles
4. Remove the cooling fan stator assembly.

4x2 vehicles
5. Remove the RH fender splash shield.

All vehicles







6. Loosen the bolt and detach the compressor manifold and tube from the A/C compressor.
- Discard the O-ring seals.







7. Disconnect the field coil electrical connector.







8. Remove the nut and the battery cable bracket.







9. Remove the ground cable and the ground stud.







10. NOTE: The lower rear bolt must be removed with the A/C compressor.

Remove the bolts and 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.