Compressor HVAC: Service and Repair
REMOVAL
WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.
CAUTION: The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver/drier can cause serious damage to the replacement A/C compressor.
NOTE: The A/C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch, clutch coil, engine, engine cylinder head or the generator.
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system.
3. Remove the air cleaner housing
4. Remove the acessory drive belt
5. Disconnect the wire harness connector from the compressor clutch field coil connector (1).
6. Remove the nuts (2) that secure the A/C suction line (3) and A/C discharge line (4) to the A/C compressor (5).
7. Disconnect the suction and discharge lines from the A/C compressor and remove and discard the dual plane seals.
8. Install plugs in, or tape over all of the opened refrigerant line fittings and the compressor ports.
9. Raise and support the vehicle.
10. Remove the front belly pan
NOTE: The bolt that secures the transmission cooler line bracket to the A/C compressor cannot be fully removed until the compressor is positioned away from the cylinder block.
11. Fully loosen the bolt (3) that secures the automatic transmission cooler line bracket (4) and A/C compressor (5) to the cylinder block (6).
12. Support the A/C compressor and remove the bolts (1 and 2) that secure the compressor to the cylinder block.
CAUTION: Use care not to deform or damage the automatic transmission cooler lines and retaining bracket when repositioning the A/C compressor.
13. Position the A/C compressor to gain clearance to the remove the bolt that secures the automatic transmission cooler line bracket to the compressor.
14. Remove the bolt that secures the automatic transmission cooler line bracket to the A/C compressor and remove the compressor from the engine compartment.
INSTALLATION
CAUTION:If the A/C compressor is being replaced, be certain to adjust the refrigerant system 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: The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver/drier can cause serious damage to the replacement A/C compressor.
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.
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. 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. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
CAUTION: Use care not to deform or damage the automatic transmission cooler lines and retaining bracket when repositioning the A/C compressor.
NOTE: The bolt that secures the transmission cooler line bracket to the A/C compressor must be installed through the bracket and the lower front mounting hole of the compressor prior to final positioning of the compressor to the cylinder block.
2. Loosely install the bolt (3) that secures the automatic transmission cooler line bracket (4) to the A/C compressor and position the compressor, bracket and bolt to the cylinder block (6).
3. Loosely install the bolts (1 and 2) that secure the A/C compressor to the cylinder block
4. Tighten the three bolts in the following order:
1.Upper front bolt to 26 Nm (19 ft. lbs.).
2.Lower front bolt to 26 Nm (19 ft. lbs.).
3.Rear bolt to 50 Nm (37 ft. lbs.).
4.Install the front belly pan
5.Lower the vehicle.
6. Remove the tape or plugs from the opened fittings on the A/C suction line (3) and the A/C discharge line (4) and the compressor ports.
7. Lubricate the new dual plane seals with clean refrigerant oil and install them onto the suction and the discharge line fittings. Use only the specified seals 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 suction and discharge lines onto the A/C compressor (5).
9. Install the nuts (2) that secure the suction and discharge lines to the A/C compressor. Tighten the nuts to 23 N.m (17 ft.lbs.).
10. Connect the wire harness to the compressor clutch field coil connector (1).
11. Install the accessory drive belt.
12. Replace the A/C receiver/drier if the A/C compressor is being replaced due to an internal failure.
13. Install the air cleaner housing.
14. Reconnect the negative battery cable.
15. Evacuate the refrigerant system.
16. Charge the refrigerant system.