Air Conditioning Compressor Replacement (4.8L, 5.3L, or 6.0L)

Air Conditioning Compressor Replacement (4.8L, 5.3L, or 6.0L)

Special Tools

J-39400-A - Halogen Leak Detector

For equivalent region tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

2. Remove the engine coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement Coolant Recovery Reservoir Replacement.

3. Remove the suction hose from the compressor. Refer to Suction Hose Replacement (4.8L, 5.3L, 6.0L) Suction Hose Replacement (4.8L, 5.3L, 6.0L).

4. Remove the discharge hose from the compressor. Refer to Discharge Hose Replacement (4.8L, 5.3L, 6.0L) Discharge Hose Replacement (4.8L, 5.3L, 6.0L).




5. Loosen the upper compressor mounting bolts (1) and leave bolts in place.

6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

7. Remove G104 from the frame and reposition ground strap.

8. Remove the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement .

9. Disconnect the compressor clutch electrical connector.




10. Remove the lower compressor mounting bolts (1).

11. Reposition the compressor and disconnect the high pressure switch connector.

12. All wheel drive only, remove the fan and fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L) Engine Coolant Fan Lower Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)Engine Coolant Fan Lower Shroud Replacement (Diesel) Engine Coolant Fan Lower Shroud Replacement (Diesel) and Fan Replacement Fan Replacement.




13. Remove the compressor (2) with the upper mounting bolts (1).

Note: When removing the sealing washers, prevent dirt and foreign material from getting onto the following sealing surfaces:

* The washers

* The hose fitting

* The compressor ports

Use a lint-free cloth in order to clean all of the sealing surfaces.

14. Remove the compressor sealing washers. Discard the compressor sealing washers.

15. If replacing the compressor, balance the refrigerant oil. Refer to Air Conditioning Compressor Oil Balancing Procedures.

Installation Procedure

1. Install the new sealing washers. Refer to Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement.

2. Connect the high pressure switch connector.





Caution: Refer to Fastener Caution Fastener Caution.

3. Install the compressor (3) with the upper (1) and lower (2) mounting bolts. Tighten the lower mounting bolts (2) to 50 Nm (37 lb ft).

4. Connect the compressor clutch electrical connector.

5. Install the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement .

6. Install G104 to the frame.

7. Lower the vehicle.




8. Tighten the upper mounting bolts (1) to 50 Nm (37 lb ft).

9. Install the discharge hose to the compressor. Refer to Discharge Hose Replacement (4.8L, 5.3L, 6.0L) Discharge Hose Replacement (4.8L, 5.3L, 6.0L).

10. Install the suction hose to the compressor. Refer to Suction Hose Replacement (4.8L, 5.3L, 6.0L) Suction Hose Replacement (4.8L, 5.3L, 6.0L).

11. All wheel drive only, install the fan and fan shroud. Refer to Fan Replacement Fan Replacement and Engine Coolant Fan Lower Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L) Engine Coolant Fan Lower Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)Engine Coolant Fan Lower Shroud Replacement (Diesel) Engine Coolant Fan Lower Shroud Replacement (Diesel).

12. Install the engine coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement Coolant Recovery Reservoir Replacement.

13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

14. Leak test the fittings of the component using the J-39400-A - leak detector.