Compressor Hose Assembly Replacement

TOOLS REQUIRED
J 39400-A Halogen Leak Detector

REMOVAL PROCEDURE




1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the battery heat shield.
3. Remove the compressor drive belt.
4. Disconnect the compressor clutch electrical connector.
5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Remove the compressor hose to compressor retaining bolt.

IMPORTANT: Prior to removal, take note of the compressor hose routing and orientation between the compressor and condenser.




7. Using a back-up wrench on the condenser fitting (2), loosen the compressor hose fitting (1) from the condenser.




8. Remove the lower compressor mounting bolts.

IMPORTANT: Cap or tape the open compressor hose and the condenser immediately to prevent contamination.




9. Disconnect the compressor hose from the condenser.
10. Discard the O-ring seal and cap or tape the compressor hose and the condenser.




11. Lower the vehicle.
12. Remove the compressor hose to accumulator retaining bolt.

IMPORTANT: Cap or tape the open compressor hose and the accumulator immediately.

13. Disconnect the compressor hose from the accumulator, discard the O-ring seal and cap or tape the compressor hose and the accumulator to prevent contamination.




14. Remove the compressor mounting nut.
15. Fully loosen the compressor mounting stud.
16. Reposition the A/C compressor forward.
17. Remove the compressor hose from the vehicle.

INSTALLATION PROCEDURE




1. Install the compressor hose into position in the vehicle.
2. Install the compressor into position on the compressor mounting bracket.
3. Install the compressor mounting stud to the engine block.
4. Install the compressor mounting bolt in the upper, forward position (net locating hole).
5. Remove the cap or tape from the compressor hose and the accumulator.
6. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the compressor hose and the accumulator.
7. Lightly coat the O-ring seal with mineral base 525 viscosity refrigerant oil.

IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the O-ring seal to enter the refrigerant system.

8. Carefully slide the new O-ring seal onto the compressor hose until seated.
Leave a light coating of the refrigerant oil to remain on the compressor hose in the area indicated ONLY.




9. Install the compressor hose to the accumulator.

NOTE: Refer to Fastener Notice in Service Precautions.

10. Install the compressor hose to accumulator retaining bolt.

Tighten
Tighten the compressor hose to accumulator retaining bolt to 20 N.m (15 lb ft).




11. Remove the cap or tape from the compressor hose end (2) and the compressor (3).
12. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the compressor hose (2) and the compressor (3)
13. Lightly coat the new seal washers (1) with mineral base 525 viscosity refrigerant oil.

IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the seal washers to enter the refrigerant system.

14. Carefully slide the new seal washers (1) onto the compressor hose (2) until seated.




15. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
16. Route the compressor hose to the condenser as noted prior to removal.
17. Remove the cap or tape from the compressor hose and the condenser.
18. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the compressor hose and the condenser.
19. Lightly coat the new O-ring seal (1) with mineral base 525 viscosity refrigerant oil.

IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the O-ring seal to enter the refrigerant system.

20. Carefully slide the new O-ring seal (1) onto the compressor hose until seated.




21. Install the lower compressor mounting bolts.




22. Install the compressor hose to the condenser.
23. Orientate the compressor hose to the condenser as noted prior to removal.




24. Using a back-up wrench on the condenser fitting (2), secure the compressor hose fitting (1) to the condenser.

Tighten
Tighten the compressor hose fitting to the condenser to 24 N.m (17 lb ft).




25. Lower the vehicle.
26. Tighten the compressor mounting stud.

Tighten
Tighten the compressor mounting stud to 9 N.m (80 lb in).

27. Tighten the compressor mounting bolts in the following sequence:
27.1. Front upper, first
27.2. Front tower, second
27.3. Rear lower, third

Tighten
Tighten the compressor mounting bolts in sequence to 40 N.m (30 lb ft).

27.4. Install the compressor mounting nut.

Tighten
Tighten the compressor mounting nut to 40 N.m (30 lb ft).




28. Connect the compressor clutch electrical connector.
29. Install the compressor drive belt.
30. Install the battery heat shield.
31. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
32. Leak test the fittings of the component using J 39400-A.