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A/C Compressor - 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 Refrigerant 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 Refrigerant Oil Level.

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 Refrigerant Oil Level . 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 Refrigerant Oil Level . 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 Refrigerant System Evacuate .
13. Charge the refrigerant system Refrigerant System Charge .
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