Air Conditioning Compressor Replacement 4.3L and 5.7L

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical 4.3L or to Drive Belt Replacement in Engine Mechanical 5.7L.
4. Disconnect the electrical connectors from the air conditioning (A/C) compressor.




Important: When removing the sealing washers, prevent dirt and foreign material from getting on the following sealing surfaces:

•	The washers

•	The block fitting

•	The A/C compressor ports

Use a lint-free cloth in order to clean all of the sealing surfaces.
5. Remove the A/C compressor hose bolt and the clamp.
6. Remove and discard the A/C compressor sealing washers.
7. Remove the bolts and the compressor from the bracket.

1. Fill the A/C compressor. If the A/C compressor is being replaced, refer to Refrigerant Oil Distribution Specifications .




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the compressor and the bolts to the bracket.

Tighten
Tighten the A/C compressor bracket bolts to 50 N·m (37 lb ft).

Important: When installing the sealing washers, prevent dirt and foreign material from getting onto the sealed surfaces of the following components:

•	The washers

•	The block fitting

•	The A/C compressor ports

Clean all of the sealing surfaces with a lint-free cloth.
Do not oil the sealing washers prior to assembly.
Do not reuse the sealing washers.
3. Install the new sealing washers onto the pilots of the hose fitting. Ensure that the washers bottom out against the surface of the hose fitting.
4. Install the refrigerant hoses on the A/C compressor.
5. Secure the refrigerant hoses with the A/C compressor hose clamp bolt.

Tighten
Tighten the A/C compressor hose clamp bolt to 35 N·m (26 lb ft).

6. Connect the electrical connectors to the A/C compressor.
7. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical 4.3L or to Drive Belt Replacement in Engine Mechanical 5.7L.
8. Connect the negative battery cable.
9. Add refrigerant to the system. Refer to Refrigerant Recovery and Recharging .
10. Inspect the system for leaks. Refer to Leak Testing .

Air Conditioning Compressor Replacement 6.5L

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical 6.5L.
4. Disconnect the electrical connectors from the air conditioning (A/C) compressor.




Important: When removing the sealing washers, prevent dirt and foreign material from getting on the following sealing surfaces:

•	The washers

•	The block fitting

•	The A/C compressor ports

Use a lint-free cloth in order to clean all of the sealing surfaces.
5. Remove the A/C compressor hose bolt and the clamp.
6. Remove and discard the A/C compressor sealing washers.
7. Remove the bolts (2) and the compressor (1) from the bracket (3).

1. Fill the A/C compressor. If the A/C compressor is being replaced, refer to Refrigerant Oil Distribution Specifications .




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the compressor (1) and the bolts (2) to the bracket (3).

Tighten
Tighten the A/C compressor bracket bolts (2) to 50 N·m (37 lb ft).

Important: When installing the sealing washers, prevent dirt and foreign material from getting onto the sealed surfaces of the following components:

•	The washers

•	The block fitting

•	The A/C compressor ports

Clean all of the sealing surfaces with a lint-free cloth.
Do not oil the sealing washers prior to assembly.
Do not reuse the sealing washers.
3. Install the new sealing washers onto the pilots of the hose fitting. Ensure that the washers bottom against the surface of the hose fitting.
4. Install the refrigerant hoses on the A/C compressor.
5. Secure the refrigerant hoses with the A/C compressor hose clamp bolt.

Tighten
Tighten the A/C compressor hose clamp bolt to 35 N·m (26 lb ft).

6. Connect the electrical connectors to the A/C compressor.
7. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical 6.5L.
8. Connect the negative battery cable.
9. Add refrigerant to the system. Refer to Refrigerant Recovery and Recharging .
10. Inspect the system for leaks. Refer to Leak Testing .

Air Conditioning Compressor Replacement 7.4L

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical 7.4L.
4. Disconnect the electrical connectors from the air conditioning (A/C) compressor.




Important: When removing the sealing washers, prevent dirt and foreign material from getting on the following sealing surfaces:

•	The washers

•	The block fitting

•	The A/C compressor ports

Use a lint-free cloth in order to clean all of the sealing surfaces.
5. Remove the A/C compressor hose bolt and the clamp.
6. Remove and discard the A/C compressor sealing washers.
7. Remove the bolts and the compressor from the bracket.

1. Fill the A/C compressor. If the A/C compressor is being replaced, refer to Refrigerant Oil Distribution Specifications .




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the compressor and the bolts to the bracket.

Tighten
Tighten the A/C compressor bracket bolts to 50 N·m (37 lb ft).

Important: When installing the sealing washers, prevent dirt and foreign material from getting onto the sealed surfaces of the following components:

•	The washers

•	The block fitting

•	The A/C compressor ports

Clean all of the sealing surfaces with a lint-free cloth.
Do not oil the sealing washers prior to assembly.
Do not reuse the sealing washers.
3. Install the new sealing washers onto the pilots of the hose fitting. Ensure that the washers bottom out against the surface of the hose fitting.
4. Install the refrigerant hoses on the A/C compressor.
5. Secure the refrigerant hoses with the A/C compressor hose clamp bolt.

Tighten
Tighten the A/C compressor hose clamp bolt to 35 N·m (26 lb ft).

6. Connect the electrical connectors to the A/C compressor.
7. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical 7.4L.
8. Connect the negative battery cable.
9. Add refrigerant to the system. Refer to Refrigerant Recovery and Recharging .
10. Inspect the system for leaks. Refer to Leak Testing .