Please refer to Section 1 for all Charging and Discharging procedures.
It may be illegal in certain areas to service air conditioning components unless you are certified and have an approved recovery/recycling station. Consult with your local authorities.
REMOVAL & INSTALLATION
See Figures 1 through 5
- Either discharge the A/C system using an approved recovery station or have the A/C discharged by a reputable repair facility.
- Disconnect the negative battery cable.
- Remove all the necessary components in order to gain access to the compressor mounting bolts.
- Remove the compressor drive belt.
To facilitate removal of the compressor belt, remove the idler pulley and bracket as an assembly beforehand from the underside of the truck.
- Disconnect the refrigerant lines. Plug or cap all openings immediately to prevent system contamination.
Be sure to use 2 wrenches (one to loosen the fitting and one to hold it in place) when disconnecting the refrigerant lines.
- Tag and detach all electrical connections.
- Unfasten the mounting bolts, then remove the compressor from the vehicle.
- Install the compressor on the engine and evenly tighten all the mounting bolts equally. On the Z24i and VG30i, tighten to 27-37 ft. lbs. (36-50 Nm); on the KA24E and VG30E, tighten to 33-44 ft. lbs. (45-60 Nm).
- Unplug and reconnect all refrigerant lines.
- Fasten all electrical connections.
- Install any other components which were removed to gain access to the compressor mounting bolts.
- Install and adjust the drive belt.
- Connect the negative battery cable.
- Either properly evacuate and charge the A/C system using an approved charging station or have the system serviced by a reputable repair facility. Make sure the oil level is correct for the compressor.
Do not leave the compressor on its side or upside down for more than a couple minutes, as the oil in the compressor will enter the low pressure chambers. Always be sure to replace the O-rings.