Compressor Replacement

Compressor Replacement


REMOVAL PROCEDURE




1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Remove the battery heat shield.
4. Remove the accessory and compressor drive belts.
5. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
6. Remove the water pump.
7. Disconnect the compressor clutch electrical connector.




8. Remove the compressor hose to compressor retaining bolt.

IMPORTANT: Cap or tape the open compressor hose immediately.

9. Disconnect the compressor hose from the compressor, discard the seal washers and cap or tape the hose end to prevent contamination.




10. Remove the compressor mounting nut.
11. Fully loosen the compressor mounting stud.




12. Remove the compressor mounting bolts.
13. Remove the compressor and the mounting stud from the vehicle.
14. Remove the compressor mounting stud from the compressor.




15. If replacing the compressor, drain as much of the oil as possible from the removed compressor, then measure the amount drained:
15.1. Drain the oil from both the suction and discharge ports of the removed compressor into a clean container.
15.2. Remove the compressor crankcase oil drain bolt (1) and drain the crankcase oil from the removed compressor into the same container.
15.3. Measure and record the amount of oil drained from the removed compressor.

This measurement will be used during installation of the replacement compressor.

INSTALLATION




1. If installing a replacement compressor, drain as much of the oil as possible from the replacement compressor, then replenish with the proper amount as indicated:
1.1. Drain the oil from both the suction and discharge ports of the replacement compressor into a clean container.
1.2. Remove the compressor crankcase oil drain bolt (1) and drain the crankcase oil from the replacement compressor into the same clean container.
1.3. Add the proper amount of NEW oil to the replacement compressor:
^ If less than 30 ml (1 oz) of oil was drained from the removed compressor, add 60 ml (2 oz) of new oil to the replacement compressor.
^ If more than 30 ml (1 oz) of oil was drained from the removed compressor, add the same amount of new oil to the replacement compressor.

NOTE: Refer to Fastener Notice in Service Precautions.

1.4. Install the compressor crankcase oil drain bolt (1) to the replacement compressor.

Tighten
Tighten the compressor crankcase oil drain bolt to 20 N.m (15 lb ft).




2. Install the compressor mounting stud to the compressor.
3. Install the compressor into position on the compressor mounting bracket.
4. Install the compressor mounting stud to the engine block.
5. Install the compressor mounting bolt in the upper, forward position (net locating hole).
6. Install the remaining compressor mounting bolts.
7. Tighten the compressor mounting bolts in the following sequence:
7.1. Front upper, first
7.2. Front lower, second
7.3. Rear lower, third

Tighten
Tighten the compressor mounting bolts in sequence to 40 N.m (30 lb ft).




8. Tighten the compressor mounting stud.

Tighten
Tighten the compressor mounting stud to 9 N.m (80 lb in).

9. Install the compressor mounting nut.

Tighten
Tighten the compressor mounting nut to 40 N.m (30 lb ft).




10. Remove the cap or tape from the compressor hose end (2).
11. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the compressor hose (2) and the compressor (3).
12. Lightly coat the new seal washers (1) with mineral base 525 viscosityrefrigerant oil.

IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the seal washers to enter the refrigerant system.

13. Carefully slide the new seal washers (1) onto the compressor hose (2) until seated.




14. Install the compressor hose to the compressor.
15. Install the compressor hose to compressor retaining bolt.

NOTE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: After tightening the compressor hose (3) to the compressor (2), there should be a slight sealing washer gap (1) of approximately 1.2 mm (3/64 inch) between the compressor hose (3) and the compressor (2).




16. Tighten the compressor hose to compressor retaining bolt.

Tighten
Tighten the compressor hose to compressor retaining bolt to 26 N.m (19 lb ft).




17. Connect the compressor clutch electrical connector.
18. Install the water pump.
19. Install the accessory and compressor drive belts.
20. Connect the negative battery cable.

Tighten
Tighten the negative battery cable bolt to 15 N.m (11 lb ft).

21. Install the battery heat shield.
22. Program the transmitters. Refer to Transmitter Programming/Synchronization in Keyless Entry.
23. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
24. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
25. Check the compressor hose to compressor joint and the compressor for leaks. Refer to Leak Testing.