A/C Compressor - Installation

4.0L ENGINE

CAUTION: If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level Refrigerant Oil Level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

CAUTION: If an internal failure of the A/C compressor has occurred, the desiccant and filter assembly within the A/C receiver/drier must be replaced Removal-Desiccant and Filter Assembly

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor Refrigerant Oil Level

NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.





1. If the A/C compressor (5) is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor Refrigerant Oil Level. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
2. Install the two studs (3) into the mounting bosses located at the front of the A/C compressor.

NOTE: When installing the A/C compressor, the two front mounting studs must be installed along with the compressor as an assembly.

3. Position the A/C compressor along with the two studs (3) into the engine compartment together as an assembly and install the studs onto the engine. Tighten the studs securely.
4. Loosely install the bolt (2) and two nuts (4) that secure the A/C compressor to the engine. Tighten each of the fasteners to 54 Nm (40 ft. lbs.) using the following sequence:
- The upper nut at front of compressor.
- The lower nut at front of compressor.
- The bolt at the rear of compressor.

5. Connect the engine wire harness connector (1) to the field coil connector.




6. Remove the plugs or tape from the opened refrigerant line fittings and compressor ports.
7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the suction and discharge line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
8. Connect the A/C suction line (1) and A/C discharge line (5) to the A/C compressor (3).
9. Install the nuts (2 and 4) that secure the A/C suction and discharge lines to the A/C compressor. Tighten the nuts to 23 Nm (17 ft. lbs.).
10. Install the accessory drive belt Accessory Drive Belt - Installation.
11. Install the accessory drive splash shield Accessory Drive Splash Shield - Installation Front Wheelhouse Splash Shield - Installation.
12. Lower the vehicle.
13. Reconnect the negative battery cable.
14. Evacuate the refrigerant system Refrigerant System Evacuate.
15. Charge the refrigerant system Refrigerant System Charge.