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 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 Thermostatic Expansion Valve (TXV), as directed by the A/C flushing or filtering procedure.
- Install a new receiver/drier as directed by the A/C flushing or filtering procedure.


NOTE: Installation of a new receiver/drier 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. Damage to the receiver/drier includes leaks in the receiver/drier, physical damage to the receiver/drier 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 receiver/drier should not be replaced.

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.

3.5L GTDI vehicles

3. Remove the Air Cleaner (ACL) outlet pipe, RH ACL (Air Cleaner) pipe to-turbocharger pipe, RH turbocharger bypass hose and the RH turbocharger-to-Charge Air Cooler (CAC) pipe.

All vehicles

4. Disconnect the clutch field coil electrical connector.

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

6. 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).


7. If equipped, remove the front skid-plate.

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

9. Remove the 3 A/C compressor bolts.
- To install, tighten to 25 Nm (18 lb-ft).


10. Remove the A/C compressor.

11. 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 .

- Install new gasket seals and O-ring seals.

- If filtering of the refrigerant system is not to be carried out, add the correct amount of clean PAG oil to the refrigerant system.


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