Compressor HVAC: Service and Repair

Air Conditioning (A/C) Compressor - 6.0L Diesel













Removal and Installation

NOTICE: If installing a new Air Conditioning (A/C) compressor due to an internal failure of the old unit, carry out the following procedures to remove contamination from the A/C system. Failure to remove contamination from the A/C system, if present, will result in poor A/C performance and/or damage to the new A/C compressor and other components.
- If A/C flushing equipment is available, carry out flushing of the A/C system prior to installing a new A/C compressor.
- 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 evaporator core orifice. For additional information, refer to Evaporator Core Orifice Service and Repair.
- Install a new suction accumulator. For additional information, refer to Suction Accumulator - 6.0L Diesel Service and Repair.


NOTE: Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the suction accumulator should not be replaced.

NOTE: A new A/C compressor may come equipped with an A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil already installed. If these components are not pre-installed, it will be necessary to transfer these parts from the old A/C compressor to the new compressor prior to installation of the A/C compressor if suitable for reuse.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. If flushing of the refrigerant system has not been carried out, recover the refrigerant.

3. Remove the drive belt form the A/C compressor pulley.

4. Remove the wire harness stud.
- To install, tighten to 47 Nm (35 lb-ft).

5. NOTE: The upper and lower rear A/C compressor bolts must be removed with the A/C compressor.

Remove the 3 A/C compressor bolts.

- To install, tighten to 25 Nm (18 lb-ft).

6. Disconnect the clutch field coil electrical connector.

7. Remove the RH front wheel and tire assembly.

8. Loosen the compressor manifold bolt and detach the compressor manifold and tube assembly.
- Discard the O-ring seals.
- To install, tighten to 21 Nm (15 lb-ft).

9. NOTE: The A/C compressor must be removed from the bottom.

Remove the A/C compressor.

10. To install, reverse the removal procedure.
- Install new O-ring seals.

- If a new A/C compressor is to be installed, the clutch assembly may need to be transferred from the old unit to the new unit. For additional information, refer to Clutch and Clutch Field Coil Service and Repair.

- If not filtering the A/C system, lubricate the refrigerant system with the correct amount of clean PAG oil.

11. If not filtering the A/C system, evacuate, leak test, and charge the refrigerant system.