COMPRESSOR-A/C
REMOVAL
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION). 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 field coil or engine.
NOTE: 2.8L engine shown in illustrations. 3.8L engine similar.
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY).
3. On 2.8L equipped models, remove the air cleaner housing (refer to 9 - ENGINE/AIR INTAKE SYSTEM/HOUSING-AIR CLEANER - REMOVAL).
4. On 3.8L equipped models, remove the coolant recovery container (refer to 7 - COOLING/ENGINE/COOLANT RECOVERY CONTAINER - REMOVAL).
5. Remove the accessory drive belt (refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
6. On 2.8L equipped models, remove the generator (refer to 8 - ELECTRICAL/CHARGING/GENERATOR - REMOVAL).
7. Remove the nuts (2) that secure the A/C discharge line (1) and A/C suction line (3) to the A/C compressor (4).
8. Disconnect the A/C discharge and suction lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
9. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports and position the refrigerant lines out of the way.
10. Disconnect the engine wire harness connector (5) from the field coil connector (6).
11. On 2.8L equipped models, remove the splash shield from the left front fender to gain access to the lower compressor retaining bolt (refer to 23 - BODY/EXTERIOR/ SPLASH SHIELD-WHEELHOUSE - REMOVAL).
12. Remove the front lower bolt (4) and the rear bolt (3) that secure the A/C compressor (2) to the mounting bracket.
13. Support the A/C compressor and remove the upper front bolt (1) that secures the A/C compressor to the mounting bracket 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 (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 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 (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL).
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.
NOTE: 2.8L engine shown in illustrations. 3.8L engine similar.
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 into the engine compartment.
3. Loosely install the three bolts (1, 3 and 4) that secure the A/C compressor to the engine. Tighten each of the fasteners to 28 N·m (21 ft. lbs.) using the following sequence:
- The upper bolt at the front of the compressor.
- The lower bolt at the front of the compressor.
- The bolt at the rear of the compressor.
4. On 2.8L equipped models, install the splash shield onto the left front fender (refer to 23 - BODY/EXTERIOR/SPLASH SHIELD-WHEELHOUSE - INSTALLATION).
5. Connect the engine wire harness connector (5) to the field coil connector (6).
6. Remove the plugs or tape from the opened refrigerant line fittings and compressor ports.
7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge and suction 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 (1) and A/C suction line (3) to the A/C compressor (4).
9. Install the nuts (2) that secure the A/C discharge and suction lines to the A/C compressor. Tighten the nuts to 23 N·m (17 ft. lbs.).
10. On 2.8L equipped models, install the generator (refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION).
11. Install the accessory drive belt (refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
12. On 2.8L equipped models, install the air cleaner housing (refer to 9 - ENGINE/AIR INTAKE SYSTEM/HOUSING-AIR CLEANER - INSTALLATION).
13. On 3.8L equipped models, install the coolant recovery container (refer to 7 - COOLING/ENGINE/COOLANT RECOVERY CONTAINER - INSTALLATION).
14. Reconnect the negative battery cable.
15. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
16. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).