Air Conditioning Compressor Replacement

Air Conditioning Compressor Replacement (3.6L Engine)

Special Tools

J 39400 Halogen Leak Tester

Removal Procedure

Warning: Refer to Safety Glasses Warning (Safety Glasses Warning).

Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
3. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
4. Remove the accessory drive belt or air conditioning drive belt. Refer to Drive Belt Replacement (Service and Repair).




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).

Note: 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 (Sealing Washer Replacement).
Discard the sealing washers.

Note: 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).

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.


10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).





Note: 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).

Note: 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 (Service and Repair).




2. Install the compressor (2) to the compressor mounting bracket (3).

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the compressor to compressor mounting bracket retaining bolts (1) and tighten to 22 Nm (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).

Note: 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 (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) and tighten to 22 Nm (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 (Service and Repair).
11. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
12. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) l.
14. Leak test the fitting of the repaired or reinstalled component using the J 39400 .