Compressor HVAC: Service and Repair

Air Conditioning (A/C) Compressor - 4.0L













Removal and Installation

NOTICE: If installing a new air conditioning (A/C) compressor due to an internal failure of the old unit, the following procedures must be carried out 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 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 evaporator core orifice, as directed by the A/C flushing or filtering procedure.
- Install a new suction accumulator as directed by the A/C flushing or filtering procedure.


NOTE: Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the suction accumulator should not be replaced.

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.

2. If flushing of the A/C system has not been carried out, recover the refrigerant.

3. Remove the Air Cleaner (ACL) outlet tube.

4. Remove the drive belt from the A/C compressor pulley.

5. Disconnect the field coil electrical connector.

6. Loosen the compressor manifold bolt and detach the compressor manifold.
- Discard the O-ring seals.

- To install, tighten to 21 Nm (15 lb-ft).

7. Remove the line bracket nut.

8. Remove the compressor manifold and tube bracket nut, and detach the compressor manifold and tube.
- To install, tighten to 25 Nm (18 lb-ft).

9. Remove the upper LH compressor nut.
- To install, tighten to 25 Nm (18 lb-ft).

10. Remove the 2 upper compressor studs.
- To install, tighten to 4 Nm (35 lb-in).

11. Remove the lower LH compressor stud.
- To install, tighten to 25 Nm (18 lb-ft).

12. Remove the compressor bolt.
- To install, tighten to 25 Nm (18 lb-ft).

13. Remove the A/C compressor.

14. To install, reverse the removal procedure.
- If a new A/C compressor is to be installed, the clutch assembly may need to be transferred from the old unit to the new unit. For additional information, refer to Clutch and Clutch Field Coil Service and Repair.

- 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.

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