Compressor Replacement

REMOVAL PROCEDURE




1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging.
2. Remove the air cleaner outlet duct.
3. Remove the drive belt.
4. Disconnect the A/C compressor clutch coil connector (1).




5. Disconnect the A/C high pressure switch connector (2).

IMPORTANT: Do not disconnect the compressor suction/discharge hose assembly from the condenser or the accumulator.

6. Remove the compressor suction/discharge hose assembly from the compressor.
7. Remove the compressor sealing washers and discard.
8. Disconnect the accelerator control cable from the throttle bracket.




9. If equipped, disconnect the cruise control cable from the throttle bracket. Refer to Cruise Control Cable Replacement (4.3L) or Cruise Control Cable Replacement (2.2L) in Cruise Control.
10. Remove the nut and throttle control cable bracket from the throttle body.
11. Remove the four compressor mounting bolts.
12. Remove the compressor from the accessory mounting bracket.
13. Drain and measure the compressor oil.
14. Inspect the oil for contamination or metal particles.

INSTALLATION PROCEDURE

IMPORTANT: Replacement compressors are shipped without oil.




1. Add oil to the new compressor by following the instruction sheets shipped with the compressor. If the instruction sheets are not available, do the following:
1.1. Drain the refrigerant oil from the removed compressor into a clean, calibrated container.
1.2. Record the amount of oil removed from the old compressor.
1.3. If the amount of oil drained from the old compressor is less than or equal to 60 ml (2 fl oz), add 60 ml (2 fl oz) of new 525 viscosity refrigerant oil to the new compressor.
1.4. If the amount of oil drained from the old compressor is greater than 60 ml (2 fl oz), add the same amount of new 525 viscosity refrigerant oil to the new compressor.
2. Install the new compressor to the accessory mounting bracket.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the four compressor mounting bolts.

Tighten
Tighten the compressor mounting bolts to 50 N.m (37 lb ft).

4. Install the throttle control cable bracket and nut to the throttle body.

Tighten
Tighten the nut to 12 N.m (106 lb in).

5. If equipped, connect the cruise control cable to the throttle cable bracket. Refer to Cruise Control Cable Replacement (4.3L) or Cruise Control Cable Replacement (2.2L) in Cruise Control.
6. Connect the accelerator control cable to the throttle cable bracket.
7. Install new compressor and suction/discharge sealing washers.
8. Install the compressor suction/discharge hose assembly to the compressor.




9. Connect the A/C high pressure switch connector (2).




10. Connect the A/C compressor clutch coil connector (1).
11. Install the drive belt.
12. Install the air cleaner outlet duct.
13. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging.