Air Conditioning (A/C) Compressor Removal/Installation

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AIR CONDITIONING (A/C) COMPRESSOR - 2.5L REMOVAL/INSTALLATION









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. If the A/C Flusher 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 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: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.
1. With the vehicle in NEUTRAL, position it on a hoist. See Lifting.

2. Recover the refrigerant. See Air Conditioning (A/C) System Discharging And Recovery.






3. Remove the RH lower engine splash shield.






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

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

CAUTION:Do not allow the A/C compressor to hang from the A/C lines or damage to the A/C lines can occur.
6. Remove the 3 A/C compressor bolts and lower the A/C compressor to allow access to the suction and discharge fitting nuts.

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

7. Remove the A/C compressor suction and discharge fitting nuts and disconnect the fittings.

- Discard the O-ring seals and gasket seals.
- To install, tighten to 15 Nm {1.5 kgf-m, 133 in-lbf}.

8. Remove the A/C compressor.

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. To install, reverse the removal procedure.

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

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