Compressor HVAC: Service and Repair

AIR CONDITIONING (A/C) COMPRESSOR







Removal and Installation

CAUTION: If installing a new air conditioning compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the air conditioning system.
- If A/C flushing equipment is available, carry out flushing of the air conditioning system prior to installing a new air conditioning compressor.
- If A/C flushing equipment is not available, carry out filtering of the air conditioning system after a new air conditioning compressor has been installed.
- Install a new thermostatic expansion valve, as directed by the A/C flushing or filtering procedure.
- Install a new receiver/drier as directed by the A/C flushing or filtering procedure.

NOTE:
- Installation of a new receiver/drier 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 receiver/drier.
- If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. If flushing of the air conditioning system has not been carried out, recover the refrigerant.
3. Remove the 3 A/C compressor pulley shield bolts and the A/C compressor pulley shield (if equipped).
4. Remove the drive belt.
5. Remove the cooling fan assembly.
6. Remove the lower radiator splash shield.
7. Remove the lower compressor nut.
- To install, tighten to 25 Nm (18 lb-ft).

8. Completely loosen the lower compressor stud.
- To install, tighten to 9 Nm (80 lb-in).

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

10. Disconnect the A/C pressure transducer electrical connector.
11. Disconnect the field coil electrical connector.
12. Loosen the compressor manifold bolt and position the compressor manifold aside.
- Discard the O-ring seals.
- To install, tighten to 21 Nm (15 lb-ft).

13. Remove the upper compressor nut.
- To install, tighten to 25 Nm (18 lb-ft).

14. Completely loosen the upper compressor stud.
- To install, tighten to 9 Nm (80 lb-in).

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

16. Remove the 2 compressor studs and the 2 compressor bolts.

17. NOTE: The A/C compressor must be removed through the opening between the coolant pump and upper radiator support.

Remove the A/C compressor.

18. To install, reverse the removal procedure.
- If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit.
- Install new O-ring seals.
- If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil.

19. If filtering of the refrigerant system is not to be carried out, evacuate, leak test and charge the refrigerant system.