Compressor HVAC: Service and Repair

Air Conditioning (A/C) Compressor - 2.0L GTDI





Removal and Installation

NOTICE: If installing a new Air Conditioning (A/C) compressor due to an internal failure of the old unit, either a flushing procedure or system filtering procedure 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 Thermostatic Expansion Valve (TXV), as directed by the A/C flushing or filtering procedure.
- Install a new receiver/drier as directed by the A/C flushing or filtering procedure.

NOTE: Installation of a new receiver/drier 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 receiver/drier. Damage to the receiver/drier includes leaks in the receiver/drier, physical damage to the receiver/drier 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 receiver/drier 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. 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 drive belt from the A/C compressor pulley.





4. Remove the A/C compressor.
1. Detach the wire harness pin-type retainer, disconnect the field coil and control valve electrical connectors.

2. Remove the A/C compressor suction and discharge fitting nuts and disconnect the fittings.
- Discard the O-ring seals and gasket seals.

- To install, tighten to 15 Nm (133 lb-in).

3. Remove the A/C compressor mounting nut, completely loosen the A/C compressor mounting stud, remove the A/C compressor bolts and remove the A/C compressor.
- To Install, tighten A/C compressor mounting stud to 9 Nm (80 lb-in).







5. To install, reverse the removal procedure.
- Install new gasket seals and O-ring seals.

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


6. Tighten the A/C compressor bolts and nut in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).