Compressor HVAC: Service and Repair
Air Conditioning (A/C) Compressor - 5.4L and 6.8L
Removal and Installation
NOTICE: If installing a new Air Conditioning (A/C) compressor due to an internal failure of the old unit, carry out the following procedures to remove contamination from the air conditioning system. Failure to remove contamination will result in poor A/C performance and/or damage to the A/C system components.
- If A/C flushing equipment is available, carry out flushing of the A/C system prior to installing a new A/C compressor.
- If A/C flushing equipment is not available, carry out filtering of the A/C system after a new A/C compressor has been installed.
- Install a new evaporator core orifice, as directed by the A/C flushing or filtering procedure.
- Install a new suction accumulator as directed by the A/C flushing or filtering procedure.
NOTE: A new A/C compressor may come equipped with an A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil already installed. If these components are not pre-installed, it will be necessary to transfer these parts from the old A/C compressor to the new compressor prior to installation of the A/C compressor if suitable for reuse.
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If flushing of the refrigerant system has not been carried out, recover the refrigerant.
3. Detach the wire harness clip from the compressor discharge line at the A/C compressor discharge fitting.
4. Remove the A/C compressor suction and discharge fitting nuts and disconnect the fittings.
- Discard the O-ring seals and gasket seals.
- To install, tighten to 15 Nm (133 lb-in).
5. Disconnect the field coil electrical connector.
6. Release the 4 lower fan shroud tabs and position the lower fan shroud to the upward position.
7. Disconnect the 2 transmission oil cooler line fittings at the transmission.
- To install, tighten to 40 Nm (30 lb-ft).
8. Remove the transmission oil cooler line support bracket nut.
- To install, tighten to 25 Nm (18 lb-ft).
9. Remove the drive belt from the A/C compressor pulley.
10. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
11. Remove the 3 A/C compressor bolts.
- To install, tighten to 25 Nm (18 lb-ft).
12. Remove the A/C compressor.
13. To install, reverse the removal procedure.
- If a new A/C compressor is to be installed, the clutch assembly may need to be transferred from the old unit to the new unit. For additional information, refer to Clutch and Clutch Field Coil Service and Repair.
- Install new gasket seals and O-ring seals.
- If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil.
14. If filtering of the refrigerant system is not to be carried out, evacuate, leak test and charge the refrigerant system.
15. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (transmission fluid should be in the cross-hatched area of the fluid level indicator).