For 1990-2009 cars

## Air Conditioning Compressor Replacement 3.6L Engine

#### Tools Required

J 39400 Halogen Leak Tester

### Removal Procedure

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement .
4. Remove the accessory drive belt or air conditioning drive belt. Refer to Drive Belt Replacement .
5. Disconnect the compressor electrical connector (1).
6. Remove the suction/discharge pipes pad to compressor retaining bolt (1).
7. Disconnect the suction/discharge pipe pad (1) from the compressor (3).

Important: The sealing washers (2) are a single use item and must be discarded after use.

8. Remove the sealing washers (2). Refer to Sealing Washer Replacement .

Discard the sealing washers.

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

9. Cap or plug the suction/discharge pipe pad (1) and the ports on the compressor (3).

Caution: Refer to Vehicle Lifting Caution in the Preface section.

10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Important: The compressor (2) must be supported before removing the compressor to compressor mounting bracket retaining bolts (1).

11. Remove the compressor to compressor mounting bracket retaining bolts (1).

Important: Remove the compressor (2) from the compressor mounting bracket (3) by sliding forwards and then upwards out of the engine compartment.

12. Remove the compressor (2) from compressor mounting bracket (3).

### Installation Procedure

1. If you are replacing the compressor, balance the compressor oil. Refer to Air Conditioning Compressor Oil Balancing .
2. Install the compressor (2) to the compressor mounting bracket (3).

Notice: Refer to Fastener Notice in the Preface section.

3. Install the compressor to compressor mounting bracket retaining bolts (1).

Tighten
Tighten the bolts to 22 N·m (16 lb ft).

4. Lower the vehicle.
5. Remove the plugs or caps from the suction/discharge pipe pad (1) and the ports on the compressor (3).

Important: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

6. Install two NEW sealing washers (2). Refer to Sealing Washer Replacement .
7. Connect the suction/discharge pipes (1) to the compressor (3).
8. Install the suction/discharge pipe pad to compressor retaining bolt (1).

Tighten
Tighten the bolt to 22 N·m (16 lb ft).

9. Install the compressor electrical connector (1).
10. Install the accessory drive belt or air conditioning drive belt. Refer to Drive Belt Replacement .
11. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement .
12. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection l.
14. Leak test the fitting of the repaired or reinstalled component using the J 39400 .

## Air Conditioning Compressor Replacement 6.0L Engine

#### Tools Required

J 39400 Halogen Leak Tester

### Removal Procedure

Caution: Refer to Safety Glasses Caution in the Preface section.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
3. Remove the radiator air deflector. Refer to Cooling Fan and Shroud Replacement.
4. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement.
5. Remove the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement.
6. Disconnect the compressor electrical connector (1).
7. Remove the suction/discharge pipes pad to compressor retaining bolt (1).
8. Disconnect the suction/discharge pipes (1) from the compressor (3).

Important: The sealing washers (2) are a single use item and must be discarded after use.

9. Remove the sealing washers (2). Refer to Sealing Washer Replacement .

Discard the sealing washers

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

10. Cap or plug the suction/discharge pipes (1) and the ports on the compressor (3).
11. Remove the compressor to compressor bracket retaining bolts (1).

Important: Remove the compressor (2) from the compressor mounting bracket (3) by sliding forwards and than tilting upwards out of the engine compartment.

12. Remove the compressor (2) from the compressor bracket (3).

### Installation Procedure

1. If you are replacing the compressor, balance the compressor oil. Refer to Air Conditioning Compressor Oil Balancing.
2. Install the compressor (2) to the compressor mounting bracket (3).

Notice: Refer to Fastener Notice in the Preface section.

3. Install the compressor to compressor mounting bracket retaining bolts (1).

Tighten
Tighten the bolts to 22 N·m (16 lb ft).

4. Remove the plugs or caps from the suction/discharge pipes (1) and the ports on the compressor (3).

Important: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

5. Install two NEW sealing washers (2). Refer to Sealing Washer Replacement.
6. Connect the suction/discharge pipes (1) to the compressor (3)
7. Install the suction/discharge pipes pad to compressor retaining bolt (1).

Tighten
Tighten the bolt to 22 N·m (16 lb ft).

8. Connect the compressor electrical connector (1).
9. Install the drive belt, Refer to Air Conditioning Compressor Belt Replacement.
10. Install the radiator air deflector. Refer to Cooling Fan and Shroud Replacement.
11. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement.
12. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
13. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
14. Leak test the fitting of the repaired or reinstalled component using the J 39400 .