Air Conditioning Compressor Replacement LH2 - Standard Cooling

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
3. Remove the drive belt. Refer to Water Pump and Air Conditioning Compressor and Power Steering Pump Belt Replacement .
4. Disconnect the cooling fan electrical connectors.
5. Disengage the surge tank inlet hose from the retaining features on the cooling fan shroud and reposition aside.
6. Remove the cooling fan shroud to radiator retaining bolts.



7. Remove power steering line to cooling fan shroud retaining bolts.
8. Disconnect the A/C line from the cooling fan shroud retainer clip.
9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .



10. Remove the front air deflector retainers.
11. Remove the front air deflector.



12. Disconnect the engine wiring harness from the engine frame and reposition.
13. Remove the transmission oil cooler lines to cooling fan shroud retaining bolts.



14. Remove the LH front wheel. Refer to Tire and Wheel Removal and Installation .
15. Remove the LH front splash shield retainers.
16. Remove the LH front splash shield (1).



17. Remove the suction line bolt from the A/C compressor.
18. Disconnect the suction line from the A/C compressor.
19. Remove and discard the O-ring.



20. Remove the discharge line bolt from the A/C compressor.
21. Disconnect the discharge line from the A/C compressor.
22. Remove and discard the O-ring.
23. Disconnect the A/C compressor electrical connector.
24. Remove the engine oil filter. Refer to Engine Oil and Oil Filter Replacement .
25. Remove the A/C compressor mounting bolts.



26. Lower the vehicle.
27. Remove the cooling fan assembly.
28. Remove the A/C compressor.
29. Replace the desiccant bag if the following conditions exist. Refer to Air Conditioning Refrigerant Desiccant Replacement .

•	Color of PAG oil is brown or black

•	Presence of foreign substances

Important: Replacement A/C compressors are charged with PAG oil. Refer to Refrigerant System Capacities .

30. If replacing the A/C compressor, balance the compressor. Refer to Air Conditioning Compressor Oil Balancing .

1. Install the A/C compressor.



2. Install the cooling fan assembly.
3. Raise the vehicle.

Notice: Refer to Fastener Notice in the Preface section.

Important: Do not tighten the A/C compressor mounting bolts until all bolts are thoroughly started.

4. Install the A/C compressor mounting bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

5. Install the engine oil filter. Refer to Engine Oil and Oil Filter Replacement .
6. Connect the A/C compressor electrical connector.



7. Install a new O-ring to the discharge line. Refer to O-Ring Replacement .
8. Connect the discharge line to the A/C compressor.
9. Install the discharge line bolt to the A/C compressor.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

10. Install a new O-ring to the suction line. Refer to O-Ring Replacement .



11. Connect the suction line to the A/C compressor.
12. Install the suction line bolt to the A/C compressor.

Tighten
Tighten the bolt to 9 N·m (80 lb in).




13. Install the LH front splash shield (1).
14. Install the LH front splash shield retainers.
15. Install the LH front wheel. Refer to Tire and Wheel Removal and Installation .



16. Install the transmission oil cooler lines to cooling fan shroud retaining bolts.

Tighten
Tighten the bolts to 6.5 N·m (58 lb in).

17. Connect the engine wiring harness to the engine frame.



18. Install the front air deflector.
19. Install the front air deflector retainers.
20. Lower the vehicle.
21. Connect the A/C line to the cooling fan shroud retainer clip.



22. Install power steering line to cooling fan shroud retaining bolts.

Tighten
Tighten the bolts to 6.5 N·m (58 lb in).

23. Install the cooling fan shroud to radiator retaining bolts.

Tighten
Tighten the bolts to 6.5 N·m (58 lb in).

24. Connect the cooling fan electrical connectors.
25. Engage the surge tank inlet hose to the retaining features on the cooling fan shroud.
26. Install the drive belt. Refer to Water Pump and Air Conditioning Compressor and Power Steering Pump Belt Replacement .



27. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
28. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
29. Leak test the fittings of the component using the J 39400-A .

Air Conditioning Compressor Replacement LY7

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Inlet Duct Replacement .

Important: It is not necessary to completely remove the power steering and A/C compressor drive belt.

3. Disconnect the drive belt from the A/C compressor. Refer to Air Conditioning Compressor and Power Steering Pump Belt Replacement .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .



5. Remove the LH front wheel. Refer to Tire and Wheel Removal and Installation .
6. Remove the LH front splash shield retainers.
7. Remove the LH front splash shield (1).



8. Remove the discharge line bolt from the A/C compressor.
9. Disconnect the discharge line from the A/C compressor.
10. Remove and discard the O-ring.



11. Remove the suction line bolt from the A/C compressor.
12. Disconnect the suction line from the A/C compressor.
13. Remove and discard the O-ring.
14. Disconnect the A/C compressor electrical connector.
15. Remove the A/C compressor mounting bolts.
16. Remove the A/C compressor.
17. Replace the desiccant bag if the following conditions exist. Refer to Air Conditioning Refrigerant Desiccant Replacement .

•	Color of PAG oil is brown or black

•	Presence of foreign substances

18. Lower the vehicle.

Important: Replacement A/C compressors are charged with PAG oil. Refer to Refrigerant System Capacities .

19. If replacing the A/C compressor, balance the compressor. Refer to Air Conditioning Compressor Oil Balancing .

1. Install the A/C compressor.
2. Raise the vehicle.

Notice: Refer to Fastener Notice in the Preface section.

Important: Do not tighten the A/C compressor mounting bolts until all bolts are thoroughly started.

3. Install the A/C compressor mounting bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

4. Connect the A/C compressor electrical connector.



5. Install a new O-ring to the discharge line. Refer to O-Ring Replacement .
6. Connect the discharge line to the A/C compressor.
7. Install the discharge line bolt to the A/C compressor.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

8. Install a new O-ring to the suction line. Refer to O-Ring Replacement .



9. Connect the suction line to the A/C compressor.
10. Install the suction line bolt to the A/C compressor.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

11. Install the LH front splash shield (1).
12. Install the LH front splash shield retainers.
13. Install the LH front wheel. Refer to Tire and Wheel Removal and Installation .



14. Lower the vehicle.
15. Connect the drive belt to the A/C compressor. Refer to Air Conditioning Compressor and Power Steering Pump Belt Replacement .
16. Install the air cleaner outlet duct. Refer to Air Cleaner Inlet Duct Replacement .
17. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
18. Leak test the fittings of the component using the J 39400-A .

Air Conditioning Compressor Replacement LH2 - Heavy Duty Cooling

Tools Required

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
3. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement - Air Conditioning, Power Steering, and Water Pump .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the LH front wheel. Refer to Tire and Wheel Removal and Installation .
6. Remove the LH front splash shield retainers.
7. Remove the LH front splash shield (1).



8. Remove the front air deflector retainers.
9. Remove the front air deflector.



10. Remove the suction line bolt from the A/C compressor.
11. Disconnect the suction line from the A/C compressor.
12. Remove and discard the O-ring.



13. Remove the discharge line bolt from the A/C compressor.
14. Disconnect the discharge line from the A/C compressor.
15. Remove and discard the O-ring.
16. Disconnect the A/C compressor electrical connector.
17. Remove the engine oil filter. Refer to Engine Oil and Oil Filter Replacement .
18. Remove the A/C compressor mounting bolts.
19. Lower the vehicle.



20. Loosen the fan nut from the crank adapter shaft using J 41240-5A .

Important: Do not attempt to remove the fan from the vehicle. The fan should be gently repositioned aside to allow for adequate clearance during the A/C compressor replacement.

21. Disconnect the fan from the crank adapter shaft and gently reposition the fan aside.
22. Remove the A/C compressor.
23. Replace the desiccant bag if the following conditions exist. Refer to Air Conditioning Refrigerant Desiccant Replacement .

•	Color of PAG oil is brown or black

•	Presence of foreign substances

Important: Replacement A/C compressors are charged with PAG oil. Refer to Refrigerant System Capacities .

24. If replacing the A/C compressor, balance the compressor. Refer to Air Conditioning Compressor Oil Balancing .

1. Install the A/C compressor.

Notice: Refer to Fastener Notice in the Preface section.

2. Connect the fan from the crank adapter shaft.



3. Tighten the fan nut to the crank adapter shaft using J 41240-5A .

Tighten
Tighten the nut to 100 N·m (74 lb ft).

4. Raise the vehicle.

Important: Do not tighten the A/C compressor mounting bolts until all bolts are thoroughly started.

5. Install the A/C compressor mounting bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

6. Install the engine oil filter. Refer to Engine Oil and Oil Filter Replacement .
7. Connect the A/C compressor electrical connector.



8. Install a new O-ring to the discharge line. Refer to O-Ring Replacement .
9. Connect the discharge line to the A/C compressor.
10. Install the discharge line bolt to the A/C compressor.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

11. Install a new O-ring to the suction line. Refer to O-Ring Replacement .



12. Connect the suction line to the A/C compressor.
13. Install the suction line bolt to the A/C compressor.

Tighten
Tighten the bolt to 9 N·m (80 lb in).




14. Install the front air deflector.
15. Install the front air deflector retainers.
16. Install the LH front splash shield (1).
17. Install the LH front splash shield retainers.
18. Install the LH front wheel. Refer to Tire and Wheel Removal and Installation .
19. Lower the vehicle.
20. Install the drive tensioner. Refer to Drive Belt Tensioner Replacement - Air Conditioning, Power Steering, and Water Pump .



21. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
22. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
23. Leak test the fittings of the component using the J 39400-A .