Compressor HVAC: Service and Repair

AIR CONDITIONING (A/C) COMPRESSOR







Removal and Installation

CAUTION: 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 A/C system. Failure to remove contamination from the A/C system, if present, will result in poor A/C performance and/or damage to the new A/C compressor and other 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 refrigerant 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:
- Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the suction accumulator should not be replaced.
- If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If flushing of the air conditioning system has not been carried out, recover the refrigerant.
3. Remove the drive belt from the A/C compressor pulley.
4. Remove the A/C compressor discharge fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).

5. Remove the A/C compressor suction fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).

6. Disconnect the clutch field coil electrical connector.
7. Disconnect the crankshaft position (CKP) sensor electrical connector and position the wire harness aside.
8. Remove the 3 A/C compressor bolts.
- To install, tighten to 25 Nm (18 lb-ft).

Rear wheel drive (RWD) vehicles
9. Remove the A/C compressor.

Four wheel drive (4WD) vehicles
10. Detach the wire harness from the compressor-to-condenser discharge line.







11. Detach the wire harness pin-type retainer from the frame.







12. Detach the wire harness pin-type retainer from the cooling fan shroud.







13. NOTE: For A/C compressor removal, the A/C compressor lines must be positioned aside and the A/C compressor must be removed from above the vehicle through the opening below the upper radiator hose connection.

Remove the A/C compressor.







All vehicles
14. To install, reverse the removal procedure.
- If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit.
- 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.

15. If filtering of the refrigerant system is not to be carried out, evacuate, leak test and charge the refrigerant system.