Compressor HVAC: Service and Repair

REMOVAL

WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION.

1. Recover the refrigerant from the refrigerant system.
2. Disconnect and isolate the battery negative cable.
3. Remove the nut that secures the suction line fitting to the top of the compressor.
4. Disconnect the suction line fitting from the compressor suction port.
5. Remove the seal from the suction line fitting and discard.
6. Install plugs in, or tape over the opened suction line fitting and the compressor suction port.
7. Remove the nut that secures the discharge line fitting to the top of the compressor.
8. Disconnect the discharge line fitting from the compressor discharge port.
9. Remove the seal from the discharge line fitting and discard.
10. Install plugs in, or tape over the opened discharge line fitting and the compressor discharge port.
11. Raise and support the vehicle.
12. Remove the serpentine accessory drive belt from the front of the engine.

Fig.1 Compressor - 2.4L Engine:

Fig.2 Compressor - 3.3L/3.8L Engine:

13. Disconnect the engine wire harness connector for the compressor clutch coil from the coil pigtail wire connector on the top of the compressor or.
14. On models with the 3.3L and 3.8L engines, disengage the retainer on the engine wire harness compressor clutch coil take out from the bracket on the top of the compressor.
15. On models with the 2.4L engine, remove the four screws that secure the compressor to the mounting bracket on the engine.
16. On models with the 3.3L and 3.8L engines, remove the three screws and one nut that secure the compressor to the engine.
17. Remove the compressor from the engine compartment.

NOTE: If a replacement compressor is being installed, be certain to drain and measure the refrigerant oil contained in the removed compressor. This will determine how much oil the replacement compressor must contain before it is installed.

INSTALLATION

NOTE: If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle.

1. Position the compressor into the engine compartment.
2. On models with the 2.4L engine, loosely install the four screws that secure the compressor to the mounting bracket on the engine. Tighten the screws to 28 Nm (21 ft. lbs.).
3. On models with the 3.3L and 3.8L engines, loosely install the three screws and one nut that secure the compressor to the engine. Tighten each of the fasteners using the following sequence to 54 Nm (40 ft. lbs.).
- The upper screw at the rear of the compressor.
- The lower screw at the rear of the compressor.
- The lower screw at the front of the compressor.
- The upper nut at the front of the compressor.
4. On models with the 3.3L and 3.8L engines only engage the retainer on the engine wire harness compressor clutch coil take out with the bracket on the top of the compressor.
5. Reconnect the engine wire harness connector for the compressor clutch coil to the coil pigtail wire connector on the top of the compressor.
6. Reinstall the serpentine accessory drive belt onto the front of the engine.
7. Lower the vehicle.
8. Remove the tape or plugs from the compressor discharge port and the discharge line fitting.
9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting.
10. Reconnect the discharge line fitting to the compressor discharge port.
11. Install and tighten the nut that secures the discharge line fitting to the compressor. Tighten the nut to 23 Nm (17 ft. lbs.).
12. Remove the tape or plugs from the compressor suction port and the suction line fitting.
13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting.
14. Reconnect the suction line fitting to the compressor suction port.
15. Install and tighten the nut that secures the suction line fitting to the compressor. Tighten the nut to 23 Nm (17 ft. lbs.).
16. Reconnect the battery negative cable.
17. Evacuate the refrigerant system.
18. Charge the refrigerant system.