Compressor HVAC: Service and Repair

REMOVAL

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.

The 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 or clutch coil, the engine, the cylinder head, or the generator.
1. Recover the refrigerant from the refrigerant system.
2. Disconnect and isolate the battery negative cable.
3. Remove the serpentine drive belt.
4. Unplug the compressor clutch coil wire harness connector.
5. Remove the suction and discharge refrigerant line manifold from the compressor. Install plugs in, or tape over all of the opened refrigerant fittings.

Fig.2 A/C Compressor - 2.4L Engine:

Fig.3 A/C Compressor- 3.7L Engine:

Fig.4 A/C Compressor - 2.5L Diesel Engine:

6. Remove the bolts that secure the compressor to the mounting bracket or or.
7. Remove the compressor from the mounting bracket.

INSTALLATION

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.

The 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 or clutch coil, the engine, the cylinder head, or the generator.

NOTE: If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle.

1. Install the compressor to the mounting bracket. Tighten the three mounting bolts to 27 Nm (20 ft. lbs.), (2.4L gasoline and 2.5L diesel engines only).

Fig.5 A/C Compressor - 3.7L Engine:

2. On the 3.7L gasoline engine install and tighten the bolts in the following sequence:
- The number one bolt (rear) is hand tightened first then tightened to 55 Nm (41 ft. lbs.).
- The number three bolt is then hand tightened and torqued to 40 Nm ( 30 ft. lbs.).
- The number two bolt is also hand tightened and torqued to 55 Nm ( 41 ft. lbs.).

3. Remove the tape or plugs from all of the opened refrigerant line fittings. Install the suction and discharge line manifold to the compressor. Tighten the fastener to 28 Nm (250 in. lbs.).
4. Install the serpentine drive belt.
5. Plug in the compressor clutch coil wire harness connector.
6. Connect the battery negative cable.
7. Evacuate the refrigerant system.
8. Charge the refrigerant system.