Air Conditioning Compressor Replacement 4.3L

Tools Required

J 39400-A Halogen Leak Detector

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .



3. Disconnect the clutch coil electrical connector (1) from the compressor.



4. Disconnect the A/C high pressure switch electrical connector (2) from the compressor.
5. Remove the drive belt. Refer to Drive Belt Replacement .



6. Remove the compressor hose assembly.
7. Remove the mounting bolts (2) from the compressor.
8. Remove the compressor from the vehicle.
9. If replacing the compressor, balance the refrigerant oil. Refer to Air Conditioning Compressor Oil Balancing .

1. Install the compressor (1) to the vehicle.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the compressor retaining bolts to the mounting bracket.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

3. Install the new sealing washers. Refer to Sealing Washer Replacement .
4. Install the compressor hose assembly.
5. Install the drive belt. Refer to Drive Belt Replacement .



6. Connect the clutch coil electrical connector (1) to the compressor.



7. Connect the A/C high pressure switch electrical connector (2) to the compressor.
8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
10. Leak test the fittings of the components using the J 39400-A .

Air Conditioning Compressor Replacement 4.8L, 5.3L, 6.0L

Special Tools

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .



2. Remove the engine coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
3. Remove the suction hose bolt from the compressor.
4. Remove the suction hose from the compressor.
5. Remove the discharge hose bolt from the compressor.
6. Remove the discharge hose from the compressor.
7. Loosen the upper compressor mounting bolts and leave bolts in place.
8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
9. Remove G104 from the frame and reposition ground strap.
10. Install a ratchet into the A/C belt tensioner adapter opening.
11. Rotate the belt tensioner clockwise in order to relieve the tension on the belt.
12. Remove the A/C belt from the pulley.
13. Disconnect the compressor clutch electrical connector.
14. Remove the lower compressor mounting bolts.
15. Reposition the compressor and disconnect the high pressure switch connector.
16. All wheel drive only, remove the fan and fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement and Fan Replacement .
17. Remove the compressor.

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

•	The washers

•	The hose fitting

•	The compressor ports

Use a lint-free cloth in order to clean all of the sealing surfaces.
18. Remove the compressor sealing washers.

Discard the compressor sealing washers.

If replacing the compressor, balance the refrigerant oil. Refer to Air Conditioning Compressor Oil Balancing .

1. Install the new sealing washers. Refer to Sealing Washer Replacement .
2. Connect the high pressure switch connector.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the compressor with the mounting bolts in the compressor.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

4. Connect the compressor clutch electrical connector.
5. Install a ratchet into the A/C belt tensioner adapter opening.
6. Rotate the belt tensioner clockwise in order to install the belt.
7. Install the A/C belt on to the pulley.
8. Install G104 to the frame.
9. Lower the vehicle.
10. Tighten the upper mounting bolts.

Tighten
Tighten the upper mounting bolts to 50 N·m (37 lb ft).

11. Install the discharge hose to the compressor.
12. Install the discharge hose bolt to the compressor.

Tighten
Tighten the bolt to 35 N·m (26 lb ft).

13. Install the suction hose to the compressor.
14. Install the suction hose bolt to the compressor.

Tighten
Tighten the bolt to 35 N·m (26 lb ft).




15. All wheel drive only, install the fan and fan shroud. Refer to Fan Replacement and Engine Coolant Fan Lower Shroud Replacement .
16. Install the engine coolant recovery reservoir. Refer to Coolant Recovery Reservoir 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 6.6L

Special Tools

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 Drive Belt Replacement .



4. Remove the discharge hose bolt (1) from the A/C compressor.
5. Remove the discharge hose (4) from the A/C compressor.
6. Remove the suction hose bolt (2) from the A/C compressor.
7. Remove the suction hose (3) from the A/C compressor.
8. Discard the sealing washers. Cap all of the openings.
9. Disconnect the A/C compressor electrical connection.



10. Remove the A/C compressor mounting bolts.
11. Remove the A/C compressor from the vehicle.

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



2. Remove the caps or tape from the hose and line ends.
3. Install the A/C compressor.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the A/C compressor mounting bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

5. Connect the A/C compressor electrical connection.
6. Install new sealing washers on the A/C compressor hoses. Refer to Sealing Washer Replacement .



7. Install the A/C discharge hose (4) to the compressor.
8. Install the A/C discharge hose bolt (1) to the A/C compressor.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

9. Install the A/C suction hose (3) to the compressor.
10. Install the A/C suction hose bolt (2) to the A/C compressor.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

11. Install the drive belt. Refer to Drive Belt Replacement .
12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fittings of the component using the J 39400-A .