Air Conditioning Compressor Replacement LG5

Tools Required

J 39400-A Halogen Leak Detector

1. Remove the right wheelhouse panel. Refer to Wheelhouse Panel Replacement .
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
3. Remove the air cleaner layer. Refer to Caterpillar® 3126 Unit Repair Manual.
4. Remove the drive belt. Refer to Caterpillar® 3126 Unit Repair Manual.
5. Disconnect the compressor clutch electrical connector.
6. Disconnect the high pressure switch connector.



7. Remove the compressor hose bolt (1) from the compressor (3).

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.
8. Remove the refrigerant hoses (2) from the compressor (3).
9. Remove the compressor sealing washers. Discard the compressor sealing washers.



10. Remove the compressor mounting bolts (1).
11. Remove the compressor (2).
12. If replacing the compressor, balance the refrigerant oil. Refer to Air Conditioning Compressor Oil Balancing .

Important: If installing a Sanden compressor on a vehicle previously equipped with a Delphi compressor, perform installation steps 1 and 2 before installing the A/C compressor.

1. Identify the clutch coil electrical connector. Refer to HVAC Connector End Views .
2. Splice the new pigtail into the wiring harness to replace the clutch coil electrical connector. Refer to Splicing Copper Wire Using Splice Sleeves .
3. Install the compressor (2).

Notice: Refer to Fastener Notice in the Preface section.




4. Install the compressor mounting bolts (1).

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

5. Install the new compressor sealing washers. Refer to Sealing Washer Replacement .



6. Install the refrigerant hose fitting (2) to the compressor (3).
7. Install the compressor hose bolt (1).

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

8. Connect the compressor clutch electrical connector.
9. Connect the high pressure switch connector.
10. Install the drive belt. Refer to Caterpillar® 3126 Unit Repair Manual.
11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
12. Leak test the fittings of the component using the J 39400-A .
13. Install the air cleaner layer. Refer to Caterpillar® 3126 Unit Repair Manual.
14. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement .

Air Conditioning Compressor Replacement L18

Tools Required

J 39400-A Halogen Leak Detector

1. Remove the right wheelhouse panel. Refer to Wheelhouse Panel Replacement .
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
3. Remove the air cleaner layer. Refer to Air Cleaner Replacement .
4. Remove the drive belt. Refer to Drive Belt Replacement .
5. Disconnect the compressor clutch electrical connector.
6. Disconnect the high pressure switch electrical connector.




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

•	The washers

•	The hose fitting

•	The compressor sealing surface

Use a lint-free cloth in order to clean all of the sealing surfaces.
7. Remove the compressor hose bolt (1).
8. Disconnect the compressor hose (2).
9. Remove the refrigerant hoses (2) from the compressor (3).
10. Remove the compressor sealing washers and discard.



11. Remove the compressor mounting bolts (1).
12. Remove the compressor (2).
13. If replacing the compressor, balance the refrigerant oil. Refer to Air Conditioning Compressor Oil Balancing .

Important: If installing a Sanden compressor on a vehicle previously equipped with a Delphi compressor, perform installation steps 1 and 2 before installing the A/C compressor.

1. Identify the clutch coil electrical connector. Refer to HVAC Connector End Views .
2. Splice the new pigtail into the wiring harness to replace the clutch coil electrical connector. Refer to Splicing Copper Wire Using Splice Sleeves .



3. Install the compressor (2).

Notice: Refer to Fastener Notice in the Preface section.

4. Install the new compressor sealing washers. Refer to Sealing Washer Replacement .
5. Install the compressor mounting bolts (1).

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

6. Install the new compressor sealing washers. Refer to Sealing Washer Replacement .



7. Connect the refrigerant hoses (2) to the compressor (3).
8. Install the compressor hose bolt (1).

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

9. Connect the compressor clutch electrical connector.
10. Connect the high pressure switch electrical connector.
11. Install the drive belt. Refer to Drive Belt Replacement .
12. Install the air cleaner layer. Refer to Air Cleaner 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 .
15. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement .

Air Conditioning Compressor Replacement LG4

Tools Required

J 39400-A Halogen Leak Detector

1. Remove the right wheelhouse panel. Refer to Wheelhouse Panel Replacement .
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
3. Remove the air cleaner layer. Refer to Air Cleaner Replacement .
4. Remove the drive belt. Refer to Drive Belt Replacement .
5. Disconnect the compressor clutch electrical connector.
6. Disconnect the high pressure switch connector.



7. Remove the compressor hose bolt (2) from the compressor (3).

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.
8. Remove the refrigerant hoses (1) from the compressor (3).
9. Remove the compressor sealing washers. Discard the compressor sealing washers.



10. Remove the compressor mounting bolts (1).
11. Remove the compressor (2).
12. If replacing the compressor, balance the refrigerant oil. Refer to Air Conditioning Compressor Oil Balancing .

Important: If installing a Sanden compressor on a vehicle previously equipped with a Delphi compressor, perform installation steps 1 and 2 before installing the A/C compressor.

1. Identify the clutch coil electrical connector. Refer to HVAC Connector End Views .
2. Splice the new pigtail into the wiring harness to replace the clutch coil electrical connector. Refer to Splicing Copper Wire Using Splice Sleeves .
3. Install the compressor (2).

Notice: Refer to Fastener Notice in the Preface section.




4. Install the compressor mounting bolts (1).

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

5. Install the new compressor sealing washers. Refer to Sealing Washer Replacement .



6. Install the refrigerant hose fitting (1) on the compressor (3).
7. Install the compressor hose bolt (2).

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

8. Connect the compressor clutch electrical connector.
9. Connect the high pressure switch connector.
10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
11. Install the drive belt. Refer to Drive Belt Replacement .
12. Install the air cleaner layer. Refer to Air Cleaner Replacement .
13. Leak test the fittings of the component using the J 39400-A .
14. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement .

Air Conditioning Compressor Replacement LLY

Tools Required

J 39400-A Halogen Leak Detector

1. Remove the left wheelhouse panel. Refer to Wheelhouse Panel Replacement .
2. Remove the air cleaner. Refer to Air Cleaner Replacement .
3. Remove the drive belt. Refer to Drive Belt Replacement .
4. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
5. Disconnect the compressor clutch electrical connector.
6. Disconnect the high pressure switch connector.




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

•	The washers

•	The hose fitting

•	The compressor sealing surface

Use a lint-free cloth in order to clean all of the sealing surfaces.
7. Remove the compressor hose bolt (1).
8. Disconnect the compressor hose.
9. Remove the refrigerant hoses (2) from the compressor (3).
10. Remove the compressor sealing washers. Discard the compressor sealing washers.



11. Remove the compressor mounting bolts (1).
12. Remove the compressor (3) from the drive belt tensioner bracket (2).
13. If replacing the compressor, balance the refrigerant oil. Refer to Air Conditioning Compressor Oil Balancing .

Important: If installing a Sanden compressor on a vehicle previously equipped with a Delphi compressor, perform installation steps 1 and 2 before installing the A/C compressor.

1. Identify the clutch coil electrical connector. Refer to HVAC Connector End Views .
2. Splice the new pigtail into the wiring harness to replace the clutch coil electrical connector. Refer to Splicing Copper Wire Using Splice Sleeves .



3. Install the compressor (3).

Notice: Refer to Fastener Notice in the Preface section.

4. Install the compressor mounting bolts (1).

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

5. Install the new compressor sealing washers. Refer to Sealing Washer Replacement .



6. Connect the refrigerant hoses (2) to the compressor (3).
7. Install the compressor hose bolt (1).

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

8. Connect the compressor clutch electrical connector.
9. Connect the high pressure switch connector.
10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
11. Install the drive belt. Refer to Drive Belt Replacement .
12. Install the air cleaner. Refer to Air Cleaner Replacement .
13. Leak test the fittings of the component using the J 39400-A .
14. Install the left wheelhouse panel. Refer to Wheelhouse Panel Replacement .