Compressor HVAC: Service and Repair

NOTE: Whenever an A/C compressor is replaced, It will be necessary to replace the A/C dehydrator and receiver tank and A/C evaporator core orifice.

Removal

1. Discharge system.
2. Drain and save radiator coolant.
3. Disconnect battery ground cable.
4. Disconnect and remove constant control relay module (CCRM).
5. Disconnect and remove fan shroud assembly, upper and lower radiator hoses and radiator.
6. Disconnect A/C clutch wire.
7. Remove top two A/C compressor retaining bolts.
8. Raise vehicle on a hoist.
9. From underneath vehicle, loosen and remove drive belt.
10. Disconnect heated oxygen sensor (HO2S) 9F472 wire connector.
11. Remove A / C muffler supporting strap bolt from subframe.
12. Disconnect A/C system hose from A/C condenser core and A/C dehydrator and receiver tank using the spring lock coupling tool. Immediately install protective caps on the open lines.
13. Remove bottom two A/C compressor retaining bolts. Be sure the A/C compressor is properly supported before bolts are removed.
14. Remove A/C compressor and A/C manifold and tubes from vehicle as a unit. The assembly can be removed from the bottom, using care not to scrape against A/C condenser core.
15. Remove A/C manifold and tubes from A/C compressor assembly.
16. If A/C compressor is to be replaced, remove the A/C clutch and A/C compressor clutch field coil.

Installation






CAUTION: Make sure correct type 0-ring seals are Installed on A/C fittings.

1. A new service replacement A/ compressor contains 207 ml (7 oz) of refrigerant oil. Prior to installing the replacement A/C compressor, drain the refrigerant oil from the removed A/C compressor into a calibrated container. Then, drain the refrigerant oil from the new A/C compressor into a clean calibrated container.

- If the amount of oil drained from the removed A/C compressor was between 90 and 148 ml (3 and 5 oz), pour the same amount of clean refrigerant oil into the new A/C compressor.

- If the amount of oil that was removed from the old A/C compressor is greater than 148 ml (5 oz), pour 148 ml (5 oz) of clean refrigerant oil into the new A/C compressor.

- If the amount of refrigerant oil that was removed from the old A/C compressor is less than 90 ml (3 oz), pour 90 ml (3 oz) of clean refrigerant oil into the new A/C compressor.

NOTE: The A/C dehydrator and receiver tank and A/C evaporator core orifice should also be replaced when the A / C compressor is replaced.

2. Using new C-ring seals lubricated with clean refrigerant oil, install manifold and tube assemblies on A/C compressor. Tighten A/C manifold and tube bolt to 18-23 Nm (13-17 lb-ft).
3. Install A/C compressor on compressor mounting bracket and install lower A/C compressor retaining bolts. Tighten bolts to 20-30 Nm (15-22 lb-ft).
4. Using new O-ring seals lubricated with clean refrigerant oil, connect the suction and discharge lines to A/C manifold and tube.
5. Install muffler support to subframe.
6. Connect H025 wire connector.
7. Install drive belt.
8. Lower vehicle to floor.
9. Install and tighten upper compressor retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft).
10. Install radiator, upper and lower radiator hoses and fan and shroud.