Air Conditioning (A/C) Compressor Removal/Installation

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AIR CONDITIONING (A/C) COMPRESSOR REMOVAL/INSTALLATION - HYBRID










CAUTION: If installing a new A/C compressor due to an internal failure of the old unit, carry out the following procedures 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. See Air Conditioning (A/C) System Flushing. 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. See Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation. Install a new thermostatic expansion valve (TXV), as directed by the A/C flushing or filtering procedure.Install a new auxiliary TXV, as directed by the A/C flushing or filtering procedure.Install a new passenger zone valve. See - Passenger Zone Valve Removal/Installation. Install a new battery zone valve. See - Battery Zone Valve Removal/Installation.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 system contamination from a failed A/C compressor or damage to the receiver/drier.

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.

1. With the vehicle in NEUTRAL, position it on a hoist. See Lifting.

2. Recover the refrigerant. See Discharging And Recovery.






3. Remove the RH lower engine splash shield.






4. Release the tensioner and remove the drive belt from the A/C compressor pulley.

5. Remove the A/C compressor manifold bolt and disconnect the manifold and tube assembly from the A/C compressor.

- Discard the O-ring seals.
- To install, tighten to 20 Nm {2.0 kgf-m, 15 ft-lbf}.

6. Disconnect the A/C clutch field coil electrical connector.

7. Remove the 4 A/C compressor bolts and the A/C compressor.

- To install, tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.

8. 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. See - Service and Repair.

- Install new O-ring seals.
- If not filtering the A/C system, lubricate the refrigerant system with the correct amount of clean PAG oil. See Refrigerant Oil Adding.


NOTE: Service A/C compressors are shipped without PAG oil installed.

NOTE: If installing a new A/C compressor, transfer the shipping caps from the new A/C compressor to the old A/C compressor after the refrigerant oil has been measured.

9. Evacuate, leak test and charge the refrigerant system. See Air Conditioning (A/C) System Evacuation And Charging.