Compressor HVAC: Service and Repair

Air Conditioning (A/C) Compressor - 6.4L 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 air conditioning system. Failure to remove contamination will result in poor A/C performance and/or damage to the A/C system 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, 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: 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.

NOTE: Installation of a new suction accumulator is not required when repairing the A/C system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

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 A/C compressor drive belt. For additional information, refer to Drive Belts, Mounts, Brackets and Accessories.

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 (133 lb-in).

5. Detach the wire harness retainer from the A/C compressor suction fitting stud.

6. Remove the A/C compressor suction fitting nut.
- To install, tighten to 15 Nm (133 lb-in).

7. Remove the engine ground cable bolt.
- To install, tighten to 47 Nm (35 lb-ft).

8. Disconnect the field coil electrical connector.

9. Remove the 3 A/C compressor bolts.
- To install, tighten to 25 Nm (18 lb-ft).

10. Disconnect the A/C compressor suction fitting and remove the A/C compressor.
- Discard the O-ring seal and gasket seal.

11. NOTE: The A/C compressor suction fitting must be positioned on the A/C compressor stud before the A/C compressor bolts are installed.

To install, reverse the removal procedure.

- 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.

- 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.

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