Compressor

REMOVAL & INSTALLATION

CAUTION
Please refer to Section 1 for all charging and discharging procedures. It may be illegal in certain areas to service air conditioning components unless you are certified. Consult with your local authorities. Always wear eye protection. Don't smoke when handling refrigerant.

4-Cylinder Engines

NOTE: For this procedure new air conditioning hose O-rings will be needed.

1. Have the system discharged by a trained and certified auto mechanic before working on this system.
2. Disconnect the negative battery cable.

   Fig. 1: Compressor assembly removal components — 4-cylinder engines

3. On the 2.0L engine, disconnect the distributor cap from the distributor and move the cap (with the wires attached) to a safe location.
4. On the 2.6L engine, remove the ignition coil and move it to a safe location. The wiring may be left intact. If you choose to remove the wiring, be certain to label each wire.
5. On all models, loosen the belt tension adjuster (idler pulley) and remove the belt. It should not be necessary to remove this pulley if only the compressor is to be removed.
6. Label and disconnect the wiring running from the compressor. Some models have more than one wire connector. Check carefully.
7. Disconnect the discharge hose and the suction hose from the compressor. As soon as the lines are free, remove the small O-rings inside the hoses and discard them. Immediately plug or cover each open line and port to prevent the entry of any dirt.
8. Identify the upper bolts holding the compressor to the engine bracket. On some models, these bolts are near the hose ports; on others the bolts are either straight through the compressor body or parallel to the body (pivot bolt). Remove the upper bolts.
9. Support the compressor and remove the lower mounting bolts. Be prepared to hold the compressor as the last bolt comes free. Note the mounting bolts may be of different lengths; they must be reinstalled correctly.

   CAUTION
   The compressor is a heavy component; be ready for the weight.

10. Remove the compressor, keeping it roughly level as it comes out. Excessive tilting will allow the compressor oil to run out.

    To install:

11. If related repairs are needed, the compressor mounting bracket(s) and adjuster pulley and/or bracket may be removed.
12. Reinstall the compressor to its bracket and install the upper and lower bolts finger tight. Once all are snug, tighten all mounting bolts.
13. Replace the O-rings in the suction and discharge hoses with new ones and install the hoses to the compressor. Make certain the hoses are properly seated and the threaded connectors are properly engaged. Tighten the fittings.
14. Proceed with reassembly following the procedure for your particular vehicle model in reverse order.
15. Have the system evacuated and recharged.
16. Adjust the compressor belt and other drive belts as necessary.
17. Start the engine and check operation of A/C system.

6-Cylinder Engines

1. Have the air conditioning system discharged by a trained and certified automotive mechanic.
2. Disconnect the negative battery cable.
3. Remove the battery and battery tray from the engine compartment.
4. Remove the radiator shroud cover.
5. Loosen the belt tension adjuster (idler pulley) and remove the belt.
6. Label and disconnect the wiring running from the compressor. Some models may have more than one wire connector. Check carefully.
7. Disconnect the discharge hose and the suction hose from the compressor. As soon as the lines are free, remove the small O-rings inside the hoses and discard them. Immediately plug or cover each open line and port to prevent the entry of any dirt.
8. Identify the upper bolts holding the compressor to the engine bracket. On some models, these bolts are near the hose ports; on others the bolts are either straight through the compressor body or parallel to the body (pivot bolt). Remove the upper bolts.
9. Support the compressor and remove the lower mounting bolts. Be prepared to hold the compressor as the last bolt comes free. Note the mounting bolts may be of different lengths; they must be reinstalled correctly.

   CAUTION
   The compressor is a heavy component; be ready for the weight.

10. Remove the compressor, keeping it roughly level as it comes out. Excessive tilting will allow the compressor oil to run out.

    Fig. 2: Air conditioning compressor and tension pulley assembly — 6-cylinder engines

    To install:

11. If related repairs are needed, the compressor mounting bracket(s) and adjuster pulley and/or bracket may now be removed.
12. Reinstall the compressor to its bracket and install the upper and lower bolts finger tight. Once all are snug, tighten the mounting bolts evenly.
13. Replace the O-rings in the suction and discharge hoses with new ones and install the hoses to the compressor. Make certain the hoses are properly seated and the threaded connectors are properly engaged. Tighten the fittings.
14. Install the radiator shroud. Install the battery tray and battery into its original position.
15. Adjust the compressor belt and other drive belts as necessary.
16. Have the system evacuated and recharged as soon as possible.
17. Start the engine and check operation of A/C system.