Air Conditioning Compressor Replacement

Compressor Replacement (4.8L, 5.3L, 6.0L)

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.




2. Remove the engine coolant recovery reservoir.
3. Remove the suction hose bolt from the compressor.
4. Remove the suction hose from the compressor.
5. Remove the discharge hose bolt from the compressor.
6. Remove the discharge hose from the compressor.
7. Loosen the upper compressor mounting bolts and leave bolts in place.
8. Raise the vehicle. Refer to Vehicle Lifting.
9. Remove G104 from the frame and reposition ground strap.
10. Install a ratchet into the A/C belt tensioner adapter opening.
11. Rotate the belt tensioner clockwise in order to relieve the tension on the belt.
12. Remove the A/C belt from the pulley.
13. Disconnect the compressor clutch electrical connector.
14. Remove the lower compressor mounting bolts.
15. Reposition the compressor and disconnect the high pressure switch connector.
16. All wheel drive only, remove the fan and fan shroud.
17. Remove the compressor.

Important: When removing the sealing washers, prevent dirt and foreign material from getting onto the following sealing surfaces:

* The washers

* The hose fitting

* The compressor ports

Use a lint-free cloth in order to clean all of the sealing surfaces.

Remove the compressor sealing washers.
Discard the compressor sealing washers.
If replacing the compressor, balance the refrigerant oil. Refer to Compressor Oil Balancing.

Installation Procedure

1. Install the new sealing washers.
2. Connect the high pressure switch connector.

Notice: Refer to Fastener Notice.

3. Install the compressor with the mounting bolts in the compressor.

Tighten the bolts to 50 N.m (37 lb ft).

4. Connect the compressor clutch electrical connector.
5. Install a ratchet into the A/C belt tensioner adapter opening.
6. Rotate the belt tensioner clockwise in order to install the belt.
7. Install the A/C belt on to the pulley.
8. Install G104 to the frame.
9. Lower the vehicle.
10. Tighten the upper mounting bolts.

Tighten the upper mounting bolts to 50 N.m (37 lb ft).

11. Install the discharge hose to the compressor.
12. Install the discharge hose bolt to the compressor.

Tighten the bolt to 35 N.m (26 lb ft).

13. Install the suction hose to the compressor.
14. Install the suction hose bolt to the compressor.

Tighten the bolt to 35 N.m (26 lb ft).




15. All wheel drive only, install the fan and fan shroud.
16. Install the engine coolant recovery reservoir.
17. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
18. Leak test the fittings of the component using the J 39400-A.