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 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 thermostatic expansion valve (TXV), as directed by the A/C flushing or filtering procedure.
- Install a new receiver/drier cartridge 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 cartridge 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 cartridge. Damage to the receiver/drier cartridge includes physical damage 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 1 hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the receiver/drier cartridge does not need to be replaced.

1. If flushing of the A/C system has not been carried out, recover the refrigerant.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Remove the lower engine splash shield.
4. Remove the drive belt from the A/C compressor pulley.
5. Disconnect the field coil electrical connector.
6. Remove the A/C compressor manifold bolt.
- Discard the gasket seals.
- To install, tighten to 15 Nm (11 lb-ft).

7. Remove the 3 secondary air injection pump bolts and position the pump aside (if equipped).
- To install, tighten to 30 Nm (22 lb-ft).

8. Remove the 3 A/C compressor bolts.
- To install, tighten to 25 Nm (18 lb-ft).

9. Remove the A/C compressor.
10. 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 gasket seals.
- If filtering of the A/C system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil.

11. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant system.