Compressor HVAC: Service and Repair

AIR CONDITIONING (A/C) COMPRESSOR







Removal and Installation

CAUTION: If installing a new air conditioning (A/C) compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the air conditioning system:
- If A/C flushing equipment is available, carry out flushing of the air conditioning 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) 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:
- If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.
- Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If flushing of the air conditioning system has not been carried out, recover the refrigerant.
3. Remove the drive belt from the A/C compressor pulley.

4x4 vehicles







4. Remove screws and the lower cooling fan shroud.

All vehicles
5. Loosen the compressor manifold bolt and detach the compressor manifold and tube assembly from the A/C compressor.
- Discard the O-ring seals.
- To install, tighten to 20 Nm (15 lb-ft).

6. Remove the transmission cooler tube support bracket nut and detach the bracket.
- To install, tighten to 25 Nm (18 lb-ft).







7. Detach the wire harness.
1 Remove the 2 wire harness bracket nuts.
2 Disconnect the clutch field coil electrical connector.

8. Disconnect the crankshaft position sensor electrical connector.
9. Detach the wire harness retainer from the A/C compressor stud-bolt.
10. Remove the 3 A/C compressor stud-bolts.
- To install, tighten to 25 Nm (18 lb-ft).

11. Remove the A/C compressor.
12. To install, reverse the removal procedure.
- If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit.
- Install new 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.

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