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Air Conditioning Compressor Replacement HP2


Object Number: 1972539 Size: MF

Callout

Component Name

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

   • Identify how to disable high voltage.
   • Identify how to test for the presence of high voltage.
   • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Failure to follow the procedures exactly as written may result in serious injury or death.

Preliminary Procedures

  1. Disable hybrid high voltage system. Refer to High Voltage Disabling and High Voltage Enabling.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  3. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement.
  4. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement.
  5. Remove the suction hose. Refer to Suction Hose Replacement
  6. Remove the discharge hose. Refer to Discharge Hose Replacement
  7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  8. Remove the engine shield. Refer to Engine Shield Replacement.
  9. Remove the oil pan skid plate. Refer to Oil Pan Skid Plate Replacement.

1

A/C Compressor Cable Bolt (Qty: 2)

Caution: High Voltage (HV) cables should never be removed from the mounting block. Removal of the individual HV cable from the mounting block may result in HV cable and/or component damage from improper:

   • Cable sealing
   • Electrical shielding
   • Terminal position assurance

Caution: Refer to Fastener Caution in the Preface section.

Tighten
9 N·m (80 lb in)

2

A/C Compressor Cable Mounting Bolt (Qty: 2)

Tighten
9 N·m (80 lb in)

3

A/C Compressor Cable

4

A/C Compressor Seal

Procedure

Remove and discard the seal.

5

A/C Compressor Bolt (Qty: 3)

Tighten
50 N·m (37 lb ft)

6

A/C Compressor

Procedure

  1. Disconnect three wire low voltage electrical connector from compressor.
  2. Insert bottom compressor bolts into compressor before installing compressor to vehicle.
  3. Reprogram A/C compressor. Refer to Air Conditioning Compressor Control Module Programming and Setup

Air Conditioning Compressor Replacement LY2, LY5, LH6, L76, L92 and LMG

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure

    Object Number: 370869 Size: SH
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  2. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
  3. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement.
  4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
  5. Remove the A/C belt from the A/C compressor.
  6. Slowly release the tension on the A/C belt tensioner.
  7. Remove the discharge hose bolt from the A/C compressor.
  8. Remove the discharge hose from the A/C compressor.
  9. Remove the suction hose bolt from the A/C compressor.
  10. Remove the suction hose from the A/C compressor.
  11. Discard the sealing washers. Cap all of the openings.
  12. Disconnect the electrical connections.

    13. Object Number: 648141 Size: SH
  13. Remove the A/C compressor mounting bolts. The lower right bolt (3) will stay with the compressor due to a lack of clearance.
  14. Remove the A/C compressor (2) from the bracket (1).
  15. If replacing the A/C compressor. Refer to Air Conditioning Compressor Oil Balancing.

Installation Procedure

    Object Number: 648141 Size: SH
  1. Install the A/C compressor (2) to the bracket (1) through the fender well. Insert the mounting bolt (3) into the lower right mounting boss before installing the A/C compressor.
  2. Install the A/C compressor to the bracket. Insert the mounting bolt into the lower right mount before installing the A/C compressor.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the A/C compressor mounting bolts and tighten to 50 N·m (37 lb ft).
  4. Connect the electrical connector to the A/C compressor.
  5. Install the A/C discharge hose to the compressor using new sealing washers. Refer to Sealing Washer Replacement.
  6. Install the A/C discharge hose bolt to the A/C compressor and tighten to 16 N·m (12 lb ft).
  7. Install the A/C suction hose to the compressor using new sealing washers. Refer to Sealing Washer Replacement.
  8. Install the A/C suction hose bolt to the A/C compressor and tighten to 16 N·m (12 lb ft).
  9. Install the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement.
  10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
  11. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement.
  12. Leak test the fittings of the component using the J 39400-A .

Air Conditioning Compressor Replacement LLY/LMM

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure

    Object Number: 657564 Size: SH
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  2. Install a ratchet into the belt tensioner adapter opening.
  3. Rotate the belt tensioner counterclockwise in order to relieve the tension on the belt.
  4. Remove the belt from the A/C compressor.
  5. Slowly release the tension on the belt tensioner.

    6. Object Number: 1240158 Size: SH
  6. Remove the discharge hose bolt (2) from the A/C compressor (3).
  7. Remove the discharge hose (1) from the A/C compressor (3).

    8. Object Number: 1240163 Size: SH
  8. Remove the suction hose bolt (2) from the A/C compressor (3).
  9. Remove the suction hose (1) from the A/C compressor (3).
  10. Discard the sealing washers. Cap all of the openings.
  11. Disconnect the electrical connections.

    12. Object Number: 652574 Size: SH
  12. Remove the A/C compressor mounting bolts.
  13. If replacing the A/C compressor. Refer to Air Conditioning Compressor Oil Balancing.

Installation Procedure

    Object Number: 652574 Size: SH
  1. Remove the caps or tape from the hose and line ends.
  2. Install the A/C compressor.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the A/C compressor mounting bolts.

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

  4. Connect the electrical connection.

    5. Object Number: 1240158 Size: SH
  5. Install the A/C discharge hose (1) to the compressor (3) using new sealing washers.
  6. Install the A/C discharge hose bolt (2) to the A/C compressor (3).

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


    Object Number: 1240163 Size: SH
  7. Install the A/C suction hose (1) to the compressor (3) using new sealing washers.
  8. Install the A/C suction hose bolt (2) to the A/C compressor (3).

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

  9. Install the drive belt. Refer to Drive Belt Replacement.
  10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
  11. Leak test the fittings of the component using the J 39400-A .

Air Conditioning Compressor Replacement LU3

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure

    Object Number: 657564 Size: SH
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  2. Install a ratchet into the belt tensioner adapter opening.
  3. Rotate the belt tensioner counterclockwise in order to relieve the tension on the belt.
  4. Remove the belt from the A/C compressor.
  5. Slowly release the tension on the belt tensioner.

    6. Object Number: 1774219 Size: SH
  6. Remove the discharge and suction hose bolt from the A/C compressor.
  7. Remove the discharge and suction hose from the A/C compressor.
  8. Discard the sealing washers. Cap all of the openings.
  9. Disconnect the electrical connections.

    10. Object Number: 1774222 Size: SH
  10. Remove the A/C compressor mounting bolts.
  11. If replacing the A/C compressor. Refer to Air Conditioning Compressor Oil Balancing.

Installation Procedure

    Object Number: 1774222 Size: SH
  1. Remove the caps or tape from the hose and line ends.
  2. Install the A/C compressor.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the A/C compressor mounting bolts.

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

  4. Connect the electrical connection.

    5. Object Number: 1774219 Size: SH
  5. Install the A/C discharge and suction hose to the compressor using new sealing washers.
  6. Install the A/C discharge and suction hose bolt to the A/C compressor.

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

  7. Install the drive belt. Refer to Drive Belt Replacement.
  8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
  9. Leak test the fittings of the component using the J 39400-A .