Compressor HVAC: Service and Repair
Air Conditioning (A/C) Compressor - Hybrid
Removal and Installation
NOTICE: Motorcraft(R) Electric A/C Compressor Oil only must be used as a refrigerant system lubricant for hybrid vehicles. Addition of any oil other than Motorcraft(R) Electric A/C Compressor Oil to the hybrid vehicle refrigerant system will damage the electric Air Conditioning (A/C) compressor and contaminate the refrigerant system.
NOTICE: Service electric Air Conditioning (A/C) compressors are shipped with a small amount of electric compressor oil already installed which may not match the nominal amount required by the refrigerant system. Before installing a new service electric A/C compressor, the correct electric compressor oil level must be determined based on the amount of oil removed along with the old electric A/C compressor. Failure to correctly match the electric compressor oil amount will result in damage to the electric A/C compressor and other refrigerant system components.
NOTICE: If installing a new Air Conditioning (A/C) compressor due to an internal failure of the old unit, the following procedures must be carried out 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 Thermostatic Expansion Valve (TXV) , as directed by the A/C flushing or filtering procedure.
- Install a new receiver/drier cartridge as directed by the A/C flushing or filtering procedure.
NOTE: Installation of a new receiver/drier cartridge 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 receiver/drier cartridge. Damage to the receiver/drier cartridge includes physical damage 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 refrigerant system before repairs are carried out, the receiver/drier cartridge does not need to be replaced.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Depower the high-voltage traction battery system.
3. Recover the refrigerant.
4. NOTICE: Failure to disconnect high-voltage cable connectors as instructed may result in damage to the connectors.
Release the clips and locking tabs and disconnect the interlock connector and the high-voltage cable connector at the Air Conditioning Compressor Module (ACCM).
- Press the locking clip in the white interlock connector and disengage the white connector before releasing the locking clip on the orange portion of the high-voltage connector. The white interlock connector will not come completely apart until the orange portion is released.
5. Detach the A/C compressor high-voltage electrical connector pin-type retainer and reposition the compressor high-voltage electrical connector below the coolant hoses.
6. Remove the condenser inlet fitting nut and disconnect the fitting.
- Discard the gasket seal.
- To install, tighten to 15 Nm (133 lb-in).
7. Disconnect the A/C compressor electrical connector.
8. Remove the A/C compressor suction fitting nut and disconnect the fitting.
- Discard the gasket seal.
- To install, tighten to 15 Nm (133 lb-in).
9. Detach the wire harness pin-type retainers from the vacuum pump bracket and A/C compressor bracket.
10. Detach the wire harness pin-type retainer from the front subframe.
11. Remove the lower rear A/C compressor bolt.
- To install, tighten to 25 Nm (18 lb-ft).
12. Remove the A/C compressor discharge fitting nut and remove the compressor-to-condenser discharge line.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (133 lb-in).
13. Remove the upper A/C compressor bolt.
- To install, tighten to 25 Nm (18 lb-ft).
14. Remove the 2 A/C compressor bracket bolts and remove the A/C compressor bracket.
- To install, tighten to 25 Nm (18 lb-ft).
15. Remove the lower front A/C compressor bolt.
- To install, tighten to 25 Nm (18 lb-ft).
16. Remove the A/C compressor.
17. NOTICE: Motorcraft(R) Electric A/C Compressor Oil only must be used as a refrigerant system lubricant for hybrid vehicles. Addition of any oil other than Motorcraft(R) Electric A/C Compressor Oil to the hybrid vehicle refrigerant system will damage the electric Air Conditioning (A/C) compressor and contaminate the refrigerant system.
To install, reverse the removal procedure.
- Install new O-ring seals and gasket seals.
- Add the correct amount of clean electric A/C compressor oil to the refrigerant system.
18. Evacuate, leak test and charge the refrigerant system.