Compressor HVAC: Service and Repair

NOTE: Whenever an A/C compressor is replaced, it will be necessary to replace the suction accumulator/drier.

REMOVAL
1. Recover the refrigerant from the A/C system following the recommended procedure.
2. Drain and save the radiator coolant.
3. Disconnect the battery ground cable.
4. Disconnect and remove the constant control relay module.
5. Disconnect and remove the fan and the shroud assembly.
6. Disconnect the upper and the lower radiator hoses.
7. Remove the radiator.
8. Disconnect the A/C compressor clutch wire at the clutch field coil connector on the A/C compressor.
9. Remove the top two A/C compressor mounting bolts.
10. Raise the vehicle on a hoist.

NOTE: The following operation should be performed from underneath the vehicle.

11. Loosen and remove the accessory drive belt.
12. Disconnect the Heated Oxygen Sensor (H02S) wire connector.
13. Remove the A/C muffler supporting strap bolt from the subframe.
14. Disconnect the A/C system hose from the condenser and the suction accumulator/drier using the spring lock coupling tool or equivalent.

CAUTION: Immediately install protective caps on the open lines.

15. Remove the bottom two A/C compressor mounting bolts. Ensure the A/C compressor is properly supported as the bolts are removed.
16. Remove the A/C compressor and the A/C manifold and tube assemblies from the vehicle as a unit. The assembly can be removed from the bottom, using care not to scrape against the A/C condenser core.
17. Remove the A/C manifold and tube assemblies from A/C compressor.
18. If the old A/C compressor is to be replaced with a new one, remove the A/C clutch and the A/C compressor clutch field coil assembly.

INSTALLATION
1. A new service replacement FS-10 A/C compressor contains 207 ml (7 oz) of specified refrigerant oil. Before installing a new A/C compressor drain 120 ml (4 oz) of refrigerant oil from the A/C compressor. This will maintain the total system oil charge within the specified limits.
2. Using new 0-ring seals, lubricated with clean refrigerant oil, install the A/C manifold and tube assemblies onto the new A/C compressor.
3. Install the A/C compressor, the A/C manifold, and the tube assemblies onto the A/C compressor mounting bracket
4. Using new 0-ring seals lubricated with clean refrigerant oil, connect the suction line to the A/C compressor and the A/C manifold and tube assembly.
5. Using new 0-ring seals lubricated with clean refrigerant oil, connect the discharge line to the A/C compressor and the A/C manifold and tube assembly.
6. Install the muffler support onto the subframe.
7. Connect the H02S wire connector.
8. Install the accessory drive belt.
9. Lower the vehicle to the floor and perform the following operations from the top.
10. Install the radiator.
11. Connect the radiator hoses and tighten the hose clamps.
12. Install the fan and the shroud assembly.
13. Install and connect the constant control relay module connector.
14. Connect the battery ground cable.

NOTE: On vehicles equipped with Electronic Engine Control (EEC), when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

15. Fill the radiator with the reserved coolant.
16. Leak-test, evacuate, and charge the A/C system following the recommended procedures.
17. Check the A/C system for proper operation.