Installation

5.9L/6.7L DIESEL ENGINES

CAUTION: If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

CAUTION: The A/C accumulator must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C accumulator can cause serious damage to the replacement A/C compressor.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor.

NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.




1. If the A/C compressor (2) is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

2. Position the A/C compressor onto the mounting bracket (3) located on the right side of the cylinder block (4).

3. Install and hand tighten the four bolts (1) that secure the A/C compressor to the mounting bracket.

4. Tighten the bolts that secure the A/C compressor to the mounting bracket to 27 Nm (20 ft. lbs.).




5. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.

6. Lubricate new O-ring seals with clean refrigerant oil and install them and a new gasket onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

7. Install the A/C suction and discharge line assembly (2) onto the A/C compressor (3).

8. Install the bolt (1) that secures the refrigerant line assembly to the A/C compressor. Tighten the bolt to 23 Nm (17 ft. lbs.).

9. Connect the wire harness to the clutch field coil wire lead connector (4).

10. Install the accessory drive belt.

11. Reconnect the negative battery cable.

12. Evacuate the refrigerant system.

13. Charge the refrigerant system.