Compressor Replacement

COMPRESSOR REPLACEMENT

TOOLS REQUIRED
- J 43600 ACR 2000 Air Conditioning Service Center
- J 39400-A Halogen Leak Detector

REMOVAL PROCEDURE




1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.




3. Remove the suction pipe from the compressor.

CAUTION: Do not remove hoses or lines before system is fully discharged. System may be under pressure and contact with R134a may cause personal injury.

NOTE: 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.

4. Install a cap on the suction pipe to prevent oil spillage and moisture entry.
5. Install plugs into the compressor suction and the discharge port to prevent loss of oil during removal.




6. Raise the vehicle. Refer to Vehicle Lifting
7. Remove the lower cradle splash shield fasteners.
8. Remove the lower cradle splash shield.




9. Remove the discharge line to compressor bolt.
10. Remove the discharge line and the seal washer from the compressor.
11. Install a cap on the discharge line to prevent oil spillage and moisture entry.




12. Using a 3/8 inch ratchet, rotate the belt tensioner counterclockwise and remove the belt from the compressor pulley.




13. Disconnect the compressor clutch electrical connector.




14. Remove the compressor mounting bolts.
15. Remove the compressor from the vehicle.

INSTALLATION PROCEDURE

IMPORTANT: Replacement compressors are shipped with the full system capacity of PAG oil.




1. If replacing the compressor, balance the compressor oil. Refer to Compressor Oil Balancing.
2. Install caps on the compressor suction and discharge ports to prevent oil spillage during installation.
3. Install the compressor to the vehicle.
4. Install the bottom and rear compressor mounting bolts.

IMPORTANT: Only finger tighten the rear and bottom compressor to engine block bolts at this time.

5. Install the upper compressor mounting bolt.

NOTE: Refer to Fastener Notice in Service Precautions.

6. Tighten the compressor mounting bolts.

Tighten the bolts to 22 N.m (17 lb ft).




7. Remove the cap from the discharge line and install a new seal washer.
8. Install the discharge line to the compressor.
9. Install the discharge line to compressor bolt.
10. Tighten the discharge line bolt.

Tighten the bolt to 16 N.m (12 lb ft).




11. Using a 3/8 inch ratchet, rotate the belt tensioner counterclockwise and install the belt on the compressor pulley.




12. Connect the compressor clutch electrical connector.




13. Install the lower cradle splash shield (1).
14. Install the splash shield fasteners.

Tighten the fasteners to 5 N.m (44 lb in).




15. Remove the cap from the suction pipe and install a new seal washer.
16. Lower the vehicle.
17. Install the suction pipe to the compressor.
18. Install the suction pipe to compressor bolt.

Tighten the bolt to 16 N.m (12 lb ft).




19. Connect the negative battery cable.
20. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
21. Using the J 39400-A , leak test the fittings of the component.