Compressor HVAC: Service and Repair

Compressor: Main Climate Control

REMOVAL

CAUTION: When installing a new A/C compressor due to an internal failure of the old unit, the following procedures must be carried out to remove contamination from the refrigerant system:
^ If A/C flushing equipment is available, carry out flushing of the refrigerant system.
^ If A/C flushing equipment is not available, carry out filtering of the refrigerant system.
^ Install a new A/C evaporator core orifice.
^ Install a new suction accumulator.

NOTE:
^ Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator.
^ The A/C compressor mounting bolts must be removed with the A/C compressor.

1. Recover the refrigerant.
2. Remove the generator.
3. Raise the vehicle.







4. Completely loosen the lower A/C compressor mounting bolts.







5. Loosen the bolt and disconnect the compressor manifold and tube assembly from the A/C compressor.
6. Lower the vehicle.







7. Disconnect the A/C compressor clutch field coil electrical connector.







8. Completely loosen the A/C compressor mounting bolt.







9. Remove the three bolts from the A/C mounting bracket.







10. Remove the bolts from the generator mounting bracket.







11. Completely loosen the generator mounting bracket bolt.







12. Lift the generator mounting bracket until the remaining bolt clears the frame rail and remove the bolt. Remove the generator mounting bracket.







13. Detach the wiring harness pin-type retainer from the A/C mounting bracket and remove the bracket.







14. Disconnect the auxiliary refrigerant line from the compressor manifold and tube assembly.
^ Discard the O-ring seal.







15. Disconnect the compressor manifold and tube assembly from the suction accumulator. Position the compressor manifold and tube assembly aside.
^ Discard the O-ring seal.







16. Completely loosen the remaining bolt and remove the A/C compressor and A/C mounting brace.
^ Discard the O-ring seals.

INSTALLATION
1. To install, reverse the removal procedure.
^ If a new A/C compressor is to be installed, the A/C field coil and the A/C clutch must be transferred from the old unit.
^ Lubricate the refrigerant system with the correct amount of clean PAG oil or equivalent. See: Refrigerant Oil Addition.
^ Install new O-ring seals lubricated with clean PAG oil or equivalent.
2. Evacuate, leak test and charge the refrigerant system.