Compressor HVAC: Service and Repair

Air Conditioning (A/C) Compressor













Removal and Installation

NOTICE: If installing a new Air Conditioning (A/C) compressor due to an internal failure of the old unit, and there is evidence of debris that escaped from the compressor, the following procedures must be carried out to remove contamination from the A/C system.
- If A/C flushing equipment is available, carry out the 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 A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, 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 system before repairs are carried out, the suction accumulator should not be replaced.

1. If flushing of the A/C system has not been carried out, recover the refrigerant.

2. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Vehicle Jacking and Lifting. Failure to follow the instructions may result in serious personal injury.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

3. Remove the drive belt from the A/C compressor pulley.

4. Disconnect the field coil electrical connector.

5. Remove the 2 A/C compressor fitting nuts and disconnect the fittings.
- Discard the gasket seals and O-ring seals.

- To install, tighten to 15 Nm (133 lb-in).

6. NOTE: The upper rear and lower rear A/C compressor studs must be removed with the A/C compressor.

Remove the 3 A/C compressor studs bolts.

- To install, tighten to 25 Nm (18 lb-ft).

7. Remove the A/C compressor.

8. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Vehicle Jacking and Lifting. Failure to follow these instructions may result in serious personal injury.

To install, reverse the removal procedure.

- Install new O-ring seals and gasket 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.

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