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, 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.
4. Remove the A/C compressor discharge fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).

5. Remove the A/C compressor suction fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).

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

Rear wheel drive (RWD) vehicles
9. Remove the A/C compressor.

Four wheel drive (4WD) vehicles







10. Detach the wire harness from the compressor-to-condenser discharge line.







11. Detach the wire harness pin-type retainer from the frame.







12. Detach the wire harness pin-type retainer from the cooling fan shroud.







13. NOTE: For A/C compressor removal, the A/C compressor lines must be positioned aside and the A/C compressor must be removed from above the vehicle through the opening below the upper radiator hose connection.

Remove the A/C compressor.

All vehicles
14. 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
- 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.

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