Compressor HVAC: Service and Repair

Air Conditioning (A/C) Compressor - 6.2L 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 Thermostatic Expansion Valve (TXV), as directed by the A/C flushing or filtering procedure.
- 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 system 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.

6.8L vehicles

4. Disconnect the Crankshaft Position (CKP) electrical connector.





All vehicles

5. Disconnect the A/C clutch field coil electrical connector and detach the wire harness clip from the A/C compressor discharge fitting stud.





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

8. Remove the A/C compressor.

9. 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 O-ring seals and gasket 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.


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