Air Conditioning Compressor Replacement

Air Conditioning 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 (Refrigerant Recovery and Recharging).




2. Remove the engine coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement (Service and Repair).
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 Lifting and Jacking the Vehicle (Service and Repair).
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. Refer to Engine Coolant Fan Lower Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L) (Service and Repair)Engine Coolant Fan Lower Shroud Replacement (6.6L) (Service and Repair) and Fan Replacement (Service and Repair).
17. Remove the compressor.

Note: 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.

18. Remove the compressor sealing washers.
Discard the compressor sealing washers.
If replacing the compressor, balance the refrigerant oil. Refer to Air Conditioning Compressor Oil Balancing (Service and Repair).

Installation Procedure

1. Install the new sealing washers. Refer to Sealing Washer Replacement (Sealing Washer Replacement).
2. Connect the high pressure switch connector.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the compressor with the mounting bolts in the compressor and tighten to50 Nm (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 and tighten to50 Nm (37 lb ft).
11. Install the discharge hose to the compressor.
12. Install the discharge hose bolt to the compressor and tighten to35 Nm (26 lb ft).
13. Install the suction hose to the compressor.
14. Install the suction hose bolt to the compressor and tighten to35 Nm (26 lb ft).




15. All wheel drive only, install the fan and fan shroud. Refer to Fan Replacement (Service and Repair) and Engine Coolant Fan Lower Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L) (Service and Repair)Engine Coolant Fan Lower Shroud Replacement (6.6L) (Service and Repair).
16. Install the engine coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement (Service and Repair).
17. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
18. Leak test the fittings of the component using the J 39400-A .