Compressor Replacement

REMOVAL

NOTICE: When servicing the compressor, keep dirt and foreign material from getting on or into the compressor parts and system. Clean tools and clean work area are important for proper service. The compressor connections and the outside of the compressor should be cleaned before any on car repairs, or before removal of the compressor. The parts must be kept clean at all times and any parts to be assembled should be cleaned with a non-petroleum based solvent and dried with air. Use only lint free cloths to wipe parts. Do not allow solvent to enter compressor or hoses.

1. Disconnect negative battery cable.
2. Recover refrigerant using an approved refrigerant recovery system. Measure the amount of oil lost during recovery and record.

IMPORTANT: Verifying the purity of the refrigerant with a refrigerant purity identifier before recovery is recommended.

IMPORTANT: Steps 3 through 9 arc only necessary if the vehicle is equipped with secondary air pump reaction system (AIR).





3. Remove nuts from combination valve studs.
4. Remove air hose.
5. Remove vacuum source hose. (There is no need to disconnect the internal vacuum hose for this procedure.)





6. Remove combination valve and gasket from rear air compressor bracket.
7. Position combination valve and gasket away from A/C compressor bracket.
8. Remove air pipe nuts from exhaust manifold studs.
9. Remove air pipe.





10. Remove accessory drive belt from compressor clutch pulley by rotating belt tensioner clockwise using a 14 mm or 9/16 in. wrench. Snap-On tool S8190A (or equivalent) can be used.





11. Disconnect compressor clutch electrical connector.

CAUTION: DO NOT REMOVE HOSES BEFORE SYSTEM IS FULLY DISCHARGED.

12. Disconnect suction and discharge hoses at compressor.
13. Install plastic bags on the open end of the low and high side hoses.





14. Remove the rear compressor to bracket bolts.
15. Remove the front compressor to bracket bolts.
16. Remove compressor.

IMPORTANT: Keep compressor level during removal to avoid any oil loss from the low or high side ports.

INSTALLATION

IMPORTANT: Keep compressor level during installation to avoid any oil loss from the low or high side ports.





1. Install compressor to front bracket with three bolts. Finger tighten only.
2. Install compressor to rear bracket with three bolts. Tighten front and rear bolts to specifications.

Front Bolts:
Torque: 49 N.m (36 ft-lbs)

Rear Bolts:
Torque: 25 N.m (19 ft-lbs)

NOTICE: Use only R-12 Refrigerant oil (mineral) to lubricate O-rings. Use of R-134a (PAG) oil will cause premature corrosion of fitting joints.

IMPORTANT: Do not lubricate the new slim line seal washer on the compressor side of the suction hose. The slim line seal washer cannot be interchanged with a typical O-ring in the A/C system. Use only suction line slim line O-rings as a replacement.





3. Remove plugs or plastic bags from suction and discharge hoses.
a. Install new suction hose to compressor slim line seal washer. Do not lubricate.
b. Lubricate O-ring.
c. Install O-ring for discharge hose to compressor.

4. Install hoses to the compressor low and high side ports. Tighten bolts to specifications.

Suction Hose:
Torque: 25 N.m (19 ft-lbs)

Discharge Hose:
Torque: 25 N.m (19 ft-lbs)





5. Connect compressor clutch electrical connector.
6. Install accessory drive belt.

NOTICE: Make sure gaskets are installed correctly or a leak will occur. If gaskets are removed from stubs, replace with new gaskets. Installation steps must be performed in sequence.

IMPORTANT: Steps 7 through 13 are only necessary if the vehicle is equipped with secondary air pump reaction system (AIR).





7. Install air pipe onto exhaust manifold studs.
8. Install air pipe into rear air compressor bracket slot.
9. Install combination valve studs into rear air compressor bracket through air pipe flange holes.
10. Install and torque nuts on combination valve studs.

Torque: 7 N.m (62 in-lbs)





11. Install and torque nuts on exhaust manifold studs.

Torque: 7 N.m (62 in-lbs)

12. Install vacuum source hose.
13. Install air hose.
14. Connect negative battery cable.

Torque: 17 N.m (151 in-lbs)

15. Set clock to proper time.
16. Evacuate, charge and leak test A/C system.
17. Run A/C performance test.