A/C Compressor - Removal
A/C COMPRESSOR - 5.7L HEV MODEL
WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury Service Precautions
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation Warning and Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury.
CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment.
NOTE: The A/C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system.
1. Disconnect the battery system using the service disconnect at the battery pack Procedures.
2. Recover the refrigerant from the refrigerant system Refrigerant System Recovery.
3. Raise and support the vehicle.
WARNING: Wait a minimum of five minutes once the high voltage battery system has been disconnected before attempting to disconnect the low and high voltage connectors from the A/C compressor. This will allow sufficient time for the self discharge function to remove high voltage from any capacitor within a module that has become separated from the high voltage bus. Failure to follow this warning may result in possible serious or fatal injury.
4. Disengage the grey Connector Position Assurance (CPA) latch (1) and disconnect the black Low Voltage (LV) connector (2) from the A/C compressor (6). Push down on the grey CPA and pull the LV connector straight out.
5. Disconnect the orange High Voltage (HV) connector (4) from the A/C compressor by moving the red tab (3) on the connector inboard towards the engine, so that the tab does not stick out of the side of the connector. Then insert a flat blade screwdriver into the slot (5) at the bottom of the HV connector to disengage the integral latch and pull the HV connector straight out.
6. Remove the bolt that secures the suction line bracket (1) to the front of the engine.
7. Remove the nuts (3) that secure the A/C suction line (2) and the A/C discharge line (4) to the A/C compressor (5).
CAUTION: A small quantity of refrigerant oil may be lost from the A/C compressor when the A/C suction and discharge lines are disconnected. Prior to removing the A/C lines from the A/C compressor, it very important to place a small clean container below the compressor to capture any refrigerant oil that may leak from the compressor suction and discharge ports. Always measure the amount of refrigerant oil lost and replace with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system.
8. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
9. Install plugs in, or tape over the opened refrigerant line fittings and the compressor ports.
10. Support the A/C compressor (3) and remove the three nuts (1) and studs ( 2) that secure the compressor to the engine.
11. Remove the A/C compressor from the engine compartment.