Air Conditioning Compressor Replacement 5.7L

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.



2. Disconnect the electrical connector (1) from the coil.
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-5.0L, 5.7L.



4. Disconnect the electrical connector (2) from the A/C compressor high pressure cutoff switch.



5. Remove the compressor and condenser hose bolt (3) from the compressor.
6. Remove the compressor and condenser hose seal washers. Refer to Compressor Sealing Washers Replacement .
7. Remove the compressor brace bolts and the nuts.
8. Remove the compressor brace.
9. Remove the compressor bolts (4).
10. Remove the compressor from the vehicle.
11. Drain and measure the compressor oil.
12. When replacing the oil in the compressor check for contamination or metal particles in the oil.

If contamination is found replace the orifice.

13. Replace the orifice. Refer to Expansion (Orifice) Tube Replacement .

Important: The compressor is shipped without oil.

1. Follow the instruction sheets shipped with the air compressor, if not available, do the following:

Add oil to the air compressor.

1.1.	Prior to installing the replacement compressor, drain the refrigerant oil from the removed compressor into a clean, calibrated measuring container.

1.2.	Record the amount of oil removed from the old compressor.

1.3.	If the amount of oil drained from the old compressor is less then or equal to 60 ml (2 fl oz) add 60 ml (2 fl oz) of new clean oil to the new compressor.

1.4.	If the amount of oil drained from the old compressor is greater then 60 ml (2 fl oz) add the same amount of new clean oil to the new compressor.

2. Install the compressor to the vehicle.




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.

3. Install the compressor bolts (4).

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

4. Install the compressor braces.
5. Install the compressor brace bolts.

Tighten

•	Tighten the compressor bolts (4) to 50 N·m (37 lb ft).

•	Tighten the bolt at the generator bracket to 25 N·m (18 lb ft).

6. Install the compressor and condenser hose seal washers. Refer to Compressor Sealing Washers Replacement .
7. Install the compressor and condenser hose bolt (3) to the compressor.

Tighten
The compressor and condenser hose bolt (3) to the compressor to 48 N·m (35 lb ft).




8. Connect the electrical connector (2) to the A/C compressor high pressure cutoff switch.
9. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-6.5L.



10. Connect the electrical connectors (1) to the coil.
11. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
12. Ensure that no leaks exist in the system. Refer to Leak Testing .

Air Conditioning Compressor Replacement 7.4L

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.



2. Disconnect the electrical connector (1) from the coil.
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-7.4L.



4. Disconnect the electrical connector (2) from the A/C compressor high pressure cutoff switch.



5. Remove the compressor and condenser hose bolt (3) from the compressor.
6. Remove the compressor and condenser hose seal washers. Refer to Compressor Sealing Washers Replacement .
7. Remove the compressor brace bolts and the nuts.
8. Remove the compressor brace.
9. Remove the compressor bolts (4).
10. Remove the compressor from the vehicle.
11. Drain and measure the compressor oil.
12. When replacing the oil in the compressor check for contamination or metal particles in the oil.

If contamination is found replace the orifice.

13. Replace the orifice. Refer to Expansion (Orifice) Tube Replacement .

Important: The compressor is shipped without oil.

1. Follow the instruction sheets shipped with the air compressor, if not available, do the following:

Add oil to the air compressor.

1.1.	Prior to installing the replacement compressor, drain the refrigerant oil from the removed compressor into a clean, calibrated measuring container.

1.2.	Record the amount of oil removed from the old compressor.

1.3.	If the amount of oil drained from the old compressor is less then or equal to 60 ml (2 fl oz) add 60 ml (2 fl oz) of new clean oil to the new compressor.

1.4.	If the amount of oil drained from the old compressor is greater then 60 ml (2 fl oz) add the same amount of new clean oil to the new compressor.

2. Install the compressor to the vehicle.




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.

3. Install the compressor bolts (4).

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

4. Install the compressor braces.
5. Install the compressor brace bolts.

Tighten

•	Tighten the compressor bolts (4) to 50 N·m (37 lb ft).

•	Tighten the bolt at the generator bracket to 25 N·m (18 lb ft).

6. Install the compressor and condenser hose seal washers. Refer to Compressor Sealing Washers Replacement .
7. Install the compressor and condenser hose bolt (3) to the compressor.

Tighten
The compressor and condenser hose bolt (3) to the compressor to 48  N·m (35 lb ft).




8. Connect the electrical connector (2) to the A/C compressor high pressure cutoff switch.
9. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-7.4L.



10. Connect the electrical connectors (1) to the coil.
11. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
12. Ensure that no leaks exist in the system. Refer to Leak Testing .

Air Conditioning Compressor Replacement 6.5L

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.



2. Disconnect the electrical connector (1) from the coil.
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-6.5L.



4. Disconnect the electrical connector (2) from the A/C compressor high pressure cutoff switch.



5. Remove the compressor and condenser hose bolt (3) from the compressor.
6. Remove the compressor and condenser hose seal washers. Refer to Compressor Sealing Washers Replacement .
7. Remove the compressor brace bolts and the nuts.
8. Remove the compressor brace.
9. Remove the compressor bolts (4).
10. Remove the compressor from the vehicle.
11. Drain and measure the compressor oil.
12. When replacing the oil in the compressor check for contamination or metal particles in the oil.

If contamination is found replace the orifice.

13. Replace the orifice. Refer to Expansion (Orifice) Tube Replacement .

Important: The compressor is shipped without oil.

1. Follow the instruction sheets shipped with the air compressor, if not available, do the following:

Add oil to the air compressor.

1.1.	Prior to installing the replacement compressor, drain the refrigerant oil from the removed compressor into a clean, calibrated measuring container.

1.2.	Record the amount of oil removed from the old compressor.

1.3.	If the amount of oil drained from the old compressor is less then or equal to 60 ml (2 fl oz) add 60 ml (2 fl oz) of new clean oil to the new compressor.

1.4.	If the amount of oil drained from the old compressor is greater then 60 ml (2 fl oz) add the same amount of new clean oil to the new compressor.

2. Install the compressor to the vehicle.




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.

3. Install the compressor bolts (4).

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

4. Install the compressor braces.
5. Install the compressor brace bolts.

Tighten

•	Tighten the compressor bolts (4) to 50 N·m (37 lb ft).

•	Tighten the bolt at the generator bracket to 25 N·m (18 lb ft).

6. Install the compressor and condenser hose seal washers. Refer to Compressor Sealing Washers Replacement .
7. Install the compressor and condenser hose bolt (3) to the compressor.

Tighten
The compressor and condenser hose bolt (3) to the compressor to 48 N·m (35 lb ft).




8. Connect the electrical connector (2) to the A/C compressor high pressure cutoff switch.
9. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-6.5L.



10. Connect the electrical connectors (1) to the coil.
11. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
12. Ensure that no leaks exist in the system. Refer to Leak Testing .