INSTALLATION
2.8L DIESEL ENGINE
CAUTION: If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT 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 accumulator must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C accumulator 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 (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL).
NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals could result in a refrigerant system leak.
1. If the A/C compressor (2) 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 (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL for more information). 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 (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL). Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
2. Position the A/C compressor onto the engine.
3. Install the four bolts (3) that secure the A/C compressor to the engine. Tighten the bolts to 24.5 N·m (18 ft. lbs.).
4. Connect the engine wire harness to the A/C clutch field coil connector (1).
NOTE: RHD model shown. LHD model similar.
5. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings 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.
7. Connect the A/C discharge line (1) and the A/C suction line (3) to the A/C compressor (6) and install the retaining bolts (4). Tighten the bolts to 12 N·m (106 in. lbs.).
8. If disconnected, connect the engine wire harness (2) to the A/C high pressure switch (5).
9. Install the front skid plate (refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - INSTALLATION).
10. Lower the vehicle.
11. Install the accessory drive belt (refer to 7 - COOLING/ACCESSORY DRIVE/BELTS-DRIVE - INSTALLATION).
12. Reconnect the negative battery cable.
13. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
14. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
3.7L ENGINE
CAUTION: If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT 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 accumulator must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C accumulator 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 (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL).
NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals 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 (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL for more information). 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 (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL). Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
2. Position the A/C compressor onto the engine and mounting bracket (4).
3. Install and hand tighten the three bolts that secure the A/C compressor to the engine and mounting bracket.
4. Tighten the mounting bolts in the following sequence:
- The rear bolt (1) to 55 N·m (41 ft. lbs.).
- The front inboard bolt (3) to 40 N·m (30 ft. lbs.).
- The front outboard bolt (2) to 55 N·m (41 ft. lbs.).
5. Connect the wire harness connector to the A/C clutch field coil (6).
6. Remove the tape or plugs from the opened refrigerant line fittings and compressor ports.
7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings 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 A/C discharge line (4) and the A/C suction line (6) to the A/C compressor (5).
9. Install the nuts (1) that secure the A/C suction and discharge lines to the A/C compressor. Tighten the nuts to 12 N·m (105 in. lbs.).
10. Connect the wire harness connector (3) to the A/C pressure transducer (2).
11. Install the accessory drive belt (refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
12. Reconnect the negative battery cable.
13. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
14. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).