Astro, Safari 1997-2005

Removal & Installation

Print

  1. Remove the air cleaner.
  2.  
  3. Remove the upper half of the fan shroud.
  4.  
  5. Recover the refrigerant from the system. Refer to Recovery and Charging the A/C System procedure in this section.
  6.  
  7. Disconnect the electrical connector from the A/C clutch.
  8.  
  9. Remove the drive belt.
  10.  
  11. Remove the engine cover.
  12.  
  13. Remove the oil filler tube.
  14.  
  15. Disconnect the electrical connector from the A/C compressor high pressure cutoff switch.

    Click image to see an enlarged view

    Fig. Electrical connector (1), compressor (2), compressor hose assembly bolt (3) and mounting bolts (4)

  16.  
  17. Remove the compressor hose assembly bolt (3) from the compressor.
  18.  
  19. Remove the compressor hose assembly seal washers.
  20.  
  21. Remove the compressor brace bolt.
  22.  
  23. Remove the compressor bolts (4).
  24.  
  25. Remove the compressor brace.
  26.  
  27. Remove the compressor from the vehicle.
  28.  
  29. If replacing the A/C compressor, drain and measure as much of the oil from the removed compressor as possible.
  30.  

To install:


NOTE
The compressor is shipped without oil.

  1. If replacing the compressor drain the PAG oil from the compressor and add the equivalent amount of new PAG oil to the new compressor. The system can also be evacuated and purged and the total system PAG oil capacity replaced
  2.  
  3. Install the compressor to the vehicle.
  4.  
  5. Install the compressor brace.
  6.  
  7. Install the compressor bolts
    1. Tighten the bolts to 37 ft lbs, (50 Nm).
    2.  

  8.  
  9. Install the brace bolt.
    1. Tighten the bolt to 18 ft. lbs. (25 Nm).
    2.  

  10.  
  11. Install the new compressor hose assembly seal washers.
  12.  
  13. Install the compressor hose assembly bolt (3) to the compressor.
    1. Tighten the bolt to 25 ft. lbs. (34 Nm).
    2.  

  14.  
  15. Connect the electrical connector to the A/C compressor high pressure cutoff switch.
  16.  
  17. Install the oil filler tube.
  18.  
  19. Install the drive belt.
  20.  
  21. Install the engine cover.
  22.  
  23. Connect the electrical connectors to the coil.
  24.  
  25. Evacuate and recharge the refrigerant system. Refer to Recovery and Charging the A/C System procedure in this section.
  26.  
  27. Leak test the fittings of the component using the J-39400-A.
  28.  
  29. Install the upper half of the fan shroud.
  30.  
  31. Install the air cleaner.
  32.  

 
label.common.footer.alt.autozoneLogo