Compressor HVAC: Service and Repair

REMOVAL
The compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.

1. Recover the refrigerant from the system.
2. Disconnect and isolate the battery negative cable.
3. Remove the serpentine drive belt. Refer to Cooling for the procedures.
4. Unplug the compressor clutch coil wire harness connector.
5. Remove the (2) refrigerant line retaining bolts that secure the suction line and discharge line to the compressor. Install plugs in, or tape over all of the opened refrigerant fittings.

Fig.2 Compressor Remove/Install - 4.0L Engine:

Fig.3 Compressor And A/C Lines - V8:

Fig.4 Compressor Remove/Install - V8 Engine - Right View:

6. Remove the bolts that secure the compressor or and.
7. Remove the compressor.

INSTALLATION

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.

Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.

High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.

NOTE: If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle.

1. Install the compressor. Tighten the 4.0L mounting bolts fastening the compressor to the block to 45-65 Nm (35-50 ft. lbs.). Tighten the mounting bolts holding the rear brace to the compressor and block to 40-55 Nm (30-40 ft. lbs.). Tighten the 4.7L compressor front mounting screws to 45-65 Nm (35-50 ft. lbs.), and the rear mounting screws to 35-45 Nm (25-35 ft. lbs.).
2. Remove the tape or plugs from all of the opened refrigerant line fittings. Install the suction line and discharge line fittings to the manifold on the compressor. Tighten the mounting bolts to 25.4 Nm (225 in. lbs.).
3. Install the serpentine drive belt. Refer to Cooling for the procedures.
4. Plug in the compressor clutch coil wire harness connector.
5. Connect the battery negative cable.
6. Evacuate the refrigerant system.
7. Charge the refrigerant system.