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Compressor HVAC: Service and Repair




Air Conditioning (A/C) Compressor













Removal and Installation

NOTICE: If installing a new Air Conditioning (A/C) compressor due to an internal failure of the old unit, the following procedures must be carried out 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.
- 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 Thermostatic Expansion Valve (TXV) and auxiliary TXV (if equipped).
- Install a new receiver/drier cartridge 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 receiver/drier cartridge 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 receiver/drier cartridge.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist.

2. If flushing of the A/C system has not been carried out, recover the refrigerant.

3. Remove the drive belt from the A/C compressor pulley.

4. Detach the wire harness retainer from the A/C compressor stud and position the wire harness aside.

5. Remove the 2 A/C compressor fitting nuts and disconnect the fittings.
- Discard the O-ring seals and gasket seals.

- To install, tighten to 15 Nm (133 lb-in).

Four-Wheel Drive (4WD) vehicles

6. Release the tab on the bottom of the cooling fan shroud and rotate the lower portion of the cooling fan shroud upward.

7. Detach the battery cable pin-type retainer from the engine block below the starter motor.





8. Remove the transmission cooler tube support bracket nut and detach the battery cable bracket and transmission cooler line bracket from the front cover stud.
- To install, tighten to 25 Nm (18 lb-ft).

All vehicles

9. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

10. Disconnect the clutch field coil electrical connector.

11. Remove the 3 A/C compressor stud 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.
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