Compressor HVAC: Service and Repair

AIR CONDITIONING (A/C) COMPRESSOR







Removal and Installation

CAUTION: If installing a new A/C compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the A/C system.
- 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: Installation of a new suction accumulator is not required when repairing the air conditioning 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.
2. Recover the refrigerant.
3. Remove the generator.







4. Disconnect the clutch field coil electrical connector.







5. Completely loosen the A/C compressor mounting bolt.
- To install, tighten to 25 Nm (18 lb-ft).







6. Remove the 3 bolts from the A/C mounting bracket.
- To install, tighten to 25 Nm (18 lb-ft).







7. Remove the 2 bolts from the generator mounting bracket.
- To install, tighten to 48 Nm (35 lb-ft).







8. Completely loosen the generator mounting bracket bolt.
- To install, tighten to 48 Nm (35 lb-ft).







9. Lift the generator mounting bracket until the remaining bolt clears the frame rail and remove the bolt. Remove the generator mounting bracket.







10. Remove the RH cooling fan and shroud assembly bolt.

11. NOTE: The 2 lower compressor bolts must be removed with the A/C compressor.

Completely loosen the 2 lower compressor bolts.
- To install, tighten to 25 Nm (18 lb-ft).

12. Remove the A/C compressor manifold bolt.
- To install, tighten to 20 Nm (15 lb-ft).

13. NOTE: The 2 upper compressor bolts must be removed with the A/C compressor.

Completely loosen the 2 upper compressor bolts.
- To install, tighten to 25 Nm (18 lb-ft).

14. Remove the A/C compressor.
- Discard the O-ring seals.

15. Remove the compressor bracket.
16. To install, reverse the removal procedure
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.

17. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant system.