Compressor HVAC: Service and Repair

AIR CONDITIONING (A/C) COMPRESSOR







Removal and Installation

CAUTION: If installing a new air conditioning (A/C) 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.
- If A/C flushing equipment is not available, carry out filtering of the A/C system after a new A/C compressor has been installed.
- Install a new thermostatic expansion valve (TXV) and TXV filter as directed by the A/C flushing or filtering procedure.
- Install a new receiver/drier cartridge 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 receiver/drier cartridge is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier cartridge.

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.
4. Detach the wire harness retainer from the A/C compressor stud and position the wire harness aside.
5. Remove the 2 A/C compressor fitting nuts and disconnect the fittings.
- Discard the O-ring seals and gasket seals.
- To install, tighten to 15 Nm (11 lb-ft).

Four wheel drive (4WD) vehicles
6. Release the tab on the bottom of the cooling fan shroud and rotate the lower portion of the cooling fan shroud upward.







7. Detach the battery cable pin-type retainer from the engine block below the starter motor.
8. Remove the transmission cooler tube support bracket nut and detach the battery cable bracket and transmission cooler line bracket from the front cover stud.
- To install, tighten to 25 Nm (18 lb-ft).

All vehicles
9. Disconnect the crankshaft position sensor electrical connector.
10. Disconnect the clutch field coil electrical connector.
11. Remove the 3 A/C compressor stud bolts.
- To install, tighten to 25 Nm (18 lb-ft).

12. Remove the A/C compressor.
13. 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 gasket seals and 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.

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