Ram 1500, 2500, 3500, 2WD and 4WD, 2001-2005

Removal & Installation

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CAUTION
Before beginning this procedure, review the warnings and cautions in the front of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.


NOTE
The compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.

  1. Recover the refrigerant from the refrigerant system, as outlined in this section.
  2.  
  3. Disconnect and isolate the battery negative cable.
  4.  
  5. Remove the serpentine drive belt, as outlined in the Engine Mechanical Section.
  6.  
  7. Unplug the compressor clutch coil wire harness connector.
  8.  
  9. Remove the bolt that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings.
  10.  
  11. Remove the four bolts that secure the compressor to the mounting bracket.
  12.  
  13. Remove the A/C compressor from the mounting bracket.

    Click image to see an enlarged view

    Fig. Exploded view of the bracket (1), A/C compressor (2), bolt and washer (3), brace (4) and bolt (5)-2001 vehicles with gasoline engines

    Exploded view of the bracket (1), A/C compressor (2), bolt and washer (3), brace (4) and bolt (5)-2001 vehicles with gasoline engines

    Click image to see an enlarged view

    Fig. Exploded view of the engine (1), bracket (2), A/C compressor (3) and bolts (4)-2001 vehicles with diesel engines

    Exploded view of the engine (1), bracket (2), A/C compressor (3) and bolts (4)-2001 vehicles with diesel engines
  14.  

To install:


NOTE
If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Refrigerant oil must be added when a accumulator, evaporator coil or condenser are replaced. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor.

  1. Install the compressor to the mounting bracket. Tighten the four mounting bolts to 18 ft. lbs. (24 Nm).
  2.  
  3. Remove the tape or plugs from all of the opened refrigerant line fittings. Install the suction and discharge line manifold to the compressor. .
  4.  
  5. Install the serpentine drive belt.
  6.  
  7. Plug in the compressor clutch coil wire harness connector.
  8.  
  9. Connect the battery negative cable.
  10.  
  11. Evacuate and charge the refrigerant system, as outlined in this section.
  12.  


CAUTION
Before beginning this procedure, review the warnings and cautions in the front of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.


NOTE
The compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.

  1. Recover the refrigerant from the refrigerant system, as outlined in this section.
  2.  
  3. Disconnect and isolate the battery negative cable.
  4.  
  5. Remove the accessory drive belt, as outlined in the Engine Mechanical Section.
  6.  
  7. Disconnect the A/C compressor clutch coil wire harness connector.
  8.  
  9. Depending on engine usage, remove the bolt or nuts that secure the suction and discharge line fittings to the A/C compressor.
  10.  
  11. Disconnect the suction and discharge line fittings from the A/C compressor.
  12.  
  13. Remove the O-ring seals from the suction and discharge line fittings and discard.
  14.  
  15. Install plugs in, or tape over all of the opened refrigerant line fittings and the compressor ports.
  16.  
  17. If equipped with the 5.7L Hemi engine, remove the nuts and bolts that secure the generator and A/C compressor support bracket and remove the bracket from the engine.
  18.  
  19. Remove the bolts that secure the A/C compressor to the mounting bracket.
  20.  
  21. Remove the A/C compressor from the engine compartment.

    Click image to see an enlarged view

    Fig. Exploded view of the compressor (4) retainers and related components-3.7L engine shown

    Exploded view of the compressor (4) retainers and related components-3.7L engine shown

    Click image to see an enlarged view

    Fig. Exploded view of the bolts (1), A/C compressor (2), bolt (3) and mounting bracket-5.7L engine

    Exploded view of the bolts (1), A/C compressor (2), bolt (3) and mounting bracket-5.7L engine

    Click image to see an enlarged view

    Fig. Exploded view of the engine block (1), bracket (2), A/C compressor (3) and bolts (4)-5.9L diesel engines

    Exploded view of the engine block (1), bracket (2), A/C compressor (3) and bolts (4)-5.9L diesel engines
  22.  

To install:


NOTE
If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Refrigerant oil must be added when a accumulator, evaporator coil or condenser are replaced. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor.

  1. Install the compressor onto the mounting bracket.
  2.  
  3. On the 3.7L and 4.7L engines, install and tighten the bolts in the following sequence:
    1. Install the inner front bolt #3 and hand-tighten.
    2.  
    3. Install the outer front bolt #2 and hand-tighten.
    4.  
    5. Install the rear bolt #1 and hand-tighten.
    6.  
    7. Tightened the inner front bolt #3 to 30 ft. lbs. (40 Nm).
    8.  
    9. Tightened the outer front bolt #2 to 41 ft. lbs. (55 Nm).
    10.  
    11. Tightened the rear bolt #1 to 41 ft. lbs. (55 Nm).
    12.  

  4.  
  5. For the 5.7L Hemi engine, install and tighten the bolts in the following sequence:
    1. Install the two long bolts into the mounting bracket and hand-tighten.
    2.  
    3. Install the rear bolt and hand-tighten.
    4.  
    5. Tightened the two long bolts to 30 ft. lbs. (40 Nm).
    6.  
    7. Tightened the rear bolt to 41 ft. lbs. (55 Nm).
    8.  

  6.  
  7. For the 5.7L Hemi engine, install the generator and A/C compressor support bracket and retaining nuts and bolts. Tighten the nuts and bolts securely.
  8.  
  9. For the 5.9L diesel engine, install and tighten the bolts in the following sequence:
    1. Install the four bolts into the mounting bracket and hand-tighten.
    2.  
    3. Tighten the four bolts to 17 ft. lbs. (24 Nm).
    4.  

  10.  
  11. Remove the tape or plugs from the opened refrigerant line fittings and compressor ports.
  12.  
  13. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction and discharge line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  14.  
  15. Install the suction and discharge line fittings onto the compressor.
  16.  
  17. Install the bolt or nuts (depending on engine application) that secure the suction and discharge line fittings to the compressor. Tighten the bolt or nuts to 20 ft. lbs. (28 Nm).
  18.  
  19. Connect the wire harness connector to the compressor clutch coil.
  20.  
  21. Install the serpentine drive belt.
  22.  
  23. Reconnect the battery negative cable.
  24.  
  25. Evacuate and charge the refrigerant system, as outlined in this section.
  26.  


CAUTION
Refer to the precautions in this section before performing this procedure.


NOTE
The compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.

Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.


WARNING
High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.

  1. Recover the refrigerant from the refrigerant system, as outlined in this section.
  2.  
  3. Disconnect and isolate the battery negative cable.
  4.  
  5. Remove the serpentine drive belt.
  6.  
  7. Unplug the compressor clutch coil wire harness connector.
  8.  
  9. Remove the suction and discharge refrigerant line manifold from the compressor, as follows:
    1. Unplug the wire harness connector from the high pressure cut-off switch.
    2.  
    3. Remove the radiator grille from the vehicle.
    4.  
    5. Remove the screw that secures the block fitting on the discharge line to the block fitting on the inlet of the condenser, and separate the fitting from the condenser.
    6.  
    7. Install plugs in, or tape over all of the opened refrigerant line fittings.
    8.  
    9. Disconnect the flare nut on the suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings.
    10.  
    11. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings.
    12.  
    13. Remove the suction and discharge line assembly from the vehicle.
    14.  

  10.  
  11. Remove the suction line jumper from the compressor, as follows:
    1. Remove the low pressure cut-off switch from the fitting on the suction line jumper.
    2.  
    3. Disconnect the flare nut on the suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings.
    4.  
    5. If the vehicle is equipped with the optional rear heater-A/C unit, go to Step d. If not, go to Step f.
    6.  
    7. Disconnect the flare nut on the underbody plumbing suction line from the threaded fitting on the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings.
    8.  
    9. Disconnect the flare nut on the underbody plumbing liquid line from the threaded fitting on the liquid line extension. Install plugs in, or tape over all of the opened refrigerant line fittings.
    10.  
    11. Remove the screw that secures the filter-drier to its mounting bracket.
    12.  
    13. Remove the screw that secures the block fitting of the suction line jumper to the outlet of the filter-drier, and separate the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings.
    14.  
    15. Remove the screw that secures the block fitting of the suction line jumper to the expansion valve, and separate the fitting from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings.
    16.  
    17. Remove the suction line jumper from the engine compartment.
    18.  

  12.  
  13. Remove the screw that secures the rear of the compressor brace to the engine intake manifold.
  14.  
  15. Remove the four screws that secure the compressor to the mounting bracket.
  16.  
  17. Remove the brace from the compressor.
  18.  
  19. Remove the compressor from the mounting bracket.

    Click image to see an enlarged view

    Fig. View of the compressor (1), compressor brace (2), bracket brace (3) and bracket assembly (4)

    View of the compressor (1), compressor brace (2), bracket brace (3) and bracket assembly (4)
  20.  

To install:


NOTE
If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle.

  1. Position the compressor to the mounting bracket.
  2.  
  3. Position the compressor brace to the compressor and the engine intake manifold.
  4.  
  5. Install the mounting screws. Tighten the compressor brace mounting screw to 20 ft. lbs. (27 Nm). Tighten the four compressor mounting screws to 30 ft. lbs. (41 Nm).
  6.  
  7. Remove the tape or plugs from all of the opened refrigerant line fittings. Install the suction and discharge line manifold to the compressor.
  8.  
  9. Install the serpentine drive belt.
  10.  
  11. Plug in the compressor clutch coil wire harness connector.
  12.  
  13. Connect the battery negative cable.
  14.  
  15. Evacuate and then charge the refrigerant system, as outlined in this section.
  16.  

3.7L & 4.7L Engines




CAUTION
Before beginning this procedure, review the warnings and cautions in the front of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.


NOTE
The compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.

  1. Recover the refrigerant from the refrigerant system, as outlined in this section.
  2.  
  3. Disconnect and isolate the battery negative cable.
  4.  
  5. Remove the accessory drive belt, as outlined in the Engine Mechanical Section.
  6.  
  7. Remove the nuts (4) that secure the A/C suction line (5) and the A/C discharge line (9) to the A/C compressor (6).

    Click image to see an enlarged view

    Fig. Remove the nuts (4) that secure the A/C suction line (5) and the A/C discharge line (9) to the A/C compressor (6)-3.7L & 4.7L Engines

    Remove the nuts (4) that secure the A/C suction line (5) and the A/C discharge line (9) to the A/C compressor (6)-3.7L & 4.7L Engines
  8.  
  9. Disconnect the refrigerant lines from the A/C compressor and remove and discard the seals.
  10.  
  11. Install plugs in, or tape over all of the opened refrigerant line fittings and the compressor ports.
  12.  
  13. Loosen the bolt (5) that secures the bracket (7) to the accessory mounting bracket (4).
  14.  
  15. Remove the three bolts (1, 6 and 3) that secure the A/C compressor (2) to the accessory mounting bracket.
  16.  
  17. Remove the A/C compressor from the engine compartment.

    Click image to see an enlarged view

    Fig. Loosen the bolt (5) that secures the bracket (7) to the accessory mounting bracket (4), then remove the three bolts (1, 6 and 3) that secure the A/C compressor (2) to the accessory mounting bracket-3.7L & 4.7L engines

    Loosen the bolt (5) that secures the bracket (7) to the accessory mounting bracket (4), then remove the three bolts (1, 6 and 3) that secure the A/C compressor (2) to the accessory mounting bracket-3.7L & 4.7L engines
  18.  

To install:


NOTE
If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Refrigerant oil must be added when a accumulator, evaporator coil or condenser are replaced. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor.

  1. Position the A/C compressor (2) onto the accessory mounting bracket (4).
  2.  
  3. Install and tighten the bolts in the following sequence:
    1. Install bolt (3) and hand tighten.
    2.  
    3. Install bolt (6) and hand tighten.
    4.  
    5. Install bolt (1) and hand tighten.
    6.  
    7. Tighten bolt (3) to 30 ft. lbs. (40 Nm).
    8.  
    9. Tighten bolt (6) to 41 ft. lbs. (55 Nm).
    10.  
    11. Tighten bolt (1) to 41 ft. lbs. (55 Nm).
    12.  
    13. Tighten bolt (5) to 41 ft. lbs. (55 Nm).
    14.  

  4.  
  5. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
  6.  
  7. Lubricate new seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  8.  
  9. Install the A/C suction line and the A/C discharge line onto the A/C compressor.
  10.  
  11. Install the nuts that secure the refrigerant lines to the A/C compressor. Tighten the nuts to 15 ft. lbs. (20 Nm).
  12.  
  13. Install the accessory drive belt.
  14.  
  15. Reconnect the negative battery cable.
  16.  
  17. Evacuate and charge the refrigerant system, as outlined in this section.
  18.  

5.7L Engine




CAUTION
Before beginning this procedure, review the warnings and cautions in the front of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.


NOTE
The compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.

  1. Recover the refrigerant from the refrigerant system, as outlined in this section.
  2.  
  3. Disconnect and isolate the battery negative cable.
  4.  
  5. Remove the accessory drive belt, as outlined in the Engine Mechanical Section.
  6.  
  7. Disconnect the wire harness connector from the clutch field coil connector on top of the A/C compressor (6) and the A/C pressure transducer (8) on the A/C discharge line (1).
  8.  
  9. Remove the nuts (4 and 7) that secure the A/C discharge line and the A/C suction line (5) to the A/C compressor.

    Click image to see an enlarged view

    Fig. Disconnect the wire harness connector from the clutch field coil connector on top of the A/C compressor (6) and the A/C pressure transducer (8) on the A/C discharge line (1). Remove the nuts (4 and 7) that secure the A/C discharge line and the A/C suction line (5) to the A/C compressor-5.7L engines

    Disconnect the wire harness connector from the clutch field coil connector on top of the A/C compressor (6) and the A/C pressure transducer (8) on the A/C discharge line (1). Remove the nuts (4 and 7) that secure the A/C discharge line and the A/C suction line (5) to the A/C compressor-5.7L engines
  10.  
  11. Disconnect the refrigerant lines from the A/C compressor and remove and discard the O-rings and dual plane seals.
  12.  
  13. Install plugs in, or tape over all of the opened refrigerant line fittings and the compressor ports.
  14.  
  15. Remove the generator support bracket from the front of the engine.
  16.  
  17. Remove the three bolts that secure the A/C compressor to the mounting bracket.
  18.  
  19. Remove the A/C compressor from the engine compartment.
  20.  

To install:


NOTE
If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Refrigerant oil must be added when a accumulator, evaporator coil or condenser are replaced. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor.

  1. Position the A/C compressor into the engine compartment.
  2.  
  3. Install and tighten the bolts that secure the A/C compressor to the mounting bracket in the following sequence:
    1. Install the two lower bolts and hand-tighten.
    2.  
    3. Install the rear bolt and hand-tighten.
    4.  
    5. Tighten the two lower bolts to 30 ft. lbs. (40 Nm).
    6.  
    7. Tighten the rear bolt to 41 ft. lbs. (55 Nm).
    8.  

  4.  
  5. Install the generator support bracket.
  6.  
  7. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
  8.  
  9. Lubricate new O-rings and dual plane seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  10.  
  11. Install the A/C discharge line and the A/C suction line onto the A/C compressor.
  12.  
  13. Install the nuts that secure the refrigerant lines to the A/C compressor. Tighten the nuts to 15 ft. lbs. (20 Nm).
  14.  
  15. Connect the wire harness connector to the clutch field coil connector and the A/C pressure transducer.
  16.  
  17. Install the accessory drive belt.
  18.  
  19. Reconnect the negative battery cable.
  20.  
  21. Evacuate and charge the refrigerant system, as outlined in this section.
  22.  

5.9L Diesel Engines




CAUTION
Before beginning this procedure, review the warnings and cautions in the front of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.


NOTE
The compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.

  1. Recover the refrigerant from the refrigerant system, as outlined in this section.
  2.  
  3. Disconnect and isolate the battery negative cable.
  4.  
  5. Remove the accessory drive belt, as outlined in the Engine Mechanical Section.
  6.  
  7. Disconnect the wire harness connector from the clutch coil connector of the A/C compressor (6).
  8.  
  9. Remove the bolt (7) that secure the A/C suction and discharge line assembly (8) to the A/C compressor.

    Click image to see an enlarged view

    Fig. Disconnect the wire harness connector from the clutch coil connector of the A/C compressor (6). Remove the bolt (7) that secure the A/C suction and discharge line assembly (8) to the A/C compressor.

    Disconnect the wire harness connector from the clutch coil connector of the A/C compressor (6). Remove the bolt (7) that secure the A/C suction and discharge line assembly (8) to the A/C compressor.
  10.  
  11. Disconnect the refrigerant line assembly from the A/C compressor and remove and discard the seals. Install plugs in, or tape over all of the opened refrigerant line fittings and the compressor ports.
  12.  
  13. Remove the four bolts that secure the A/C compressor to the mounting bracket located on the right side of the cylinder block.
  14.  
  15. Remove the A/C compressor from the engine compartment.
  16.  

To install:


NOTE
If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Refrigerant oil must be added when a accumulator, evaporator coil or condenser are replaced. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor.

  1. Position the A/C compressor into the engine compartment.
  2.  
  3. Install and hand-tighten the four bolts that secure the A/C compressor to the mounting bracket. Tighten the bolts that secure the A/C compressor to the mounting bracket to 17 ft. lbs. (23 Nm).
  4.  
  5. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
  6.  
  7. Lubricate new seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  8.  
  9. Install the A/C suction and discharge line assembly onto the A/C compressor.
  10.  
  11. Install the bolt that secures the refrigerant line assembly to the A/C compressor. Tighten the bolt to 20 ft. lbs. (28 Nm).
  12.  
  13. Connect the wire harness connector to the clutch coil connector of the A/C compressor.
  14.  
  15. Install the accessory drive belt.
  16.  
  17. Reconnect the negative battery cable.
  18.  
  19. Evacuate and charge the refrigerant system, as outlined in this section.
  20.  

Diesel Engines




CAUTION
Before beginning this procedure, review the warnings and cautions in the front of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.


NOTE
The compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.

  1. Recover the refrigerant from the refrigerant system, as outlined in this section.
  2.  
  3. Disconnect and isolate the battery negative cable.
  4.  
  5. Remove the accessory drive belt, as outlined in the Engine Mechanical Section.
  6.  
  7. Disconnect the compressor clutch coil wire harness connector.
  8.  
  9. Remove the bolt that secures the refrigerant line manifold to the A/C compressor. Install plugs in, or tape over all of the opened refrigerant line fittings.
  10.  
  11. Remove the four bolts that secure the A/C compressor to the mounting bracket and remove the compressor.

    Click image to see an enlarged view

    Fig. Exploded view of the engine block (1), bracket (2), A/C compressor (3) and bolts (4)-5.9L diesel engines

    Exploded view of the engine block (1), bracket (2), A/C compressor (3) and bolts (4)-5.9L diesel engines
  12.  

To install:


NOTE
If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Refrigerant oil must be added when a accumulator, evaporator coil or condenser are replaced. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor.

  1. Install the A/C compressor to the mounting bracket. Tighten the four mounting bolts to 18 ft. lbs. (24 Nm).
  2.  
  3. Remove the tape or plugs from all of the opened refrigerant line fittings. Install the suction and discharge line manifold to the compressor.
  4.  
  5. Install the accessory drive belt.
  6.  
  7. Connect the compressor clutch coil wire harness connector.
  8.  
  9. Reconnect the battery negative cable.
  10.  
  11. Evacuate and charge the refrigerant system, as outlined in this section.
  12.  

Gasoline Engines




CAUTION
Before beginning this procedure, review the warnings and cautions in the front of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.


NOTE
The compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.

  1. Recover the refrigerant from the refrigerant system, as outlined in this section.
  2.  
  3. Disconnect and isolate the battery negative cable.
  4.  
  5. Remove the accessory drive belt, as outlined in the Engine Mechanical Section.
  6.  
  7. Disconnect the compressor clutch coil wire harness connector.
  8.  
  9. For 3.7L, 4.7L and 5.7L engines, remove the suction and discharge refrigerant line manifold from the A/C compressor:
    1. Remove the nut that secures the suction line fitting to the compressor inlet port.
    2.  
    3. Disconnect the suction line from the compressor.
    4.  
    5. Remove the O-ring seal from the suction line fitting and discard.
    6.  
    7. Install plugs in, or tape over the suction line fitting and compressor inlet port.
    8.  
    9. Remove the secondary retaining clip from the spring-lock coupler that secures the suction line to the accumulator outlet tube.

      Click image to see an enlarged view

      Fig. View of a typical A/C accumulator-RH inner fender (1), accumulator inlet tube (2), A/C line secondary retaining clip (3), evaporator outlet tube (4), bolts (5), accumulator (6), suction line (7), A/C low pressure service port (8) and A/C line secondary retaining clip (9)

      View of a typical A/C accumulator-RH inner fender (1), accumulator inlet tube (2), A/C line secondary retaining clip (3), evaporator outlet tube (4), bolts (5), accumulator (6), suction line (7), A/C low pressure service port (8) and A/C line secondary retaining clip (9)
    10.  
    11. Using the proper A/C line disconnect tool, disconnect the suction line from the accumulator outlet tube.
    12.  
    13. Remove the O-ring seal from the accumulator outlet tube fitting and discard.
    14.  
    15. Install plugs in, or tape over the opened suction line and the accumulator outlet tube fitting.
    16.  
    17. Remove the nut that secures the discharge line fitting to the condenser inlet port.
    18.  
    19. Disconnect the discharge line from the A/C condenser.
    20.  
    21. Remove the O-ring seal from the discharge line fitting and discard.
    22.  
    23. Install plugs in, or tape over the discharge line fitting and condenser inlet port.
    24.  
    25. Remove the nut that secures the discharge line fitting to the A/C compressor.
    26.  
    27. Disconnect the discharge line from the A/C compressor.
    28.  
    29. Remove the O-ring seal from the discharge line fitting and discard.
    30.  
    31. Install plugs in, or tape over the discharge line fitting and compressor outlet port.
    32.  
    33. Remove the discharge line from the engine compartment.
    34.  
    35. If necessary, remove the A/C pressure transducer from the discharge line.
    36.  

  10.  
  11. For 5.9L gas engines, remove the suction and discharge refrigerant line manifold from the A/C compressor:
    1. Disconnect the wire harness connector from the A/C high pressure switch.
    2.  
    3. Disconnect the suction line from the accumulator and remove and discard the O-ring seal.
    4.  
    5. Remove the nut that secures the discharge line to the condenser inlet port.
    6.  
    7. Disconnect the discharge line from the A/C condenser and remove and discard the gasket.
    8.  
    9. Remove the nut that secures the refrigerant line support bracket to the stud on the compressor mounting bracket.
    10.  
    11. Remove the bolt that secures the suction/discharge line fitting to the A/C compressor.
    12.  
    13. Disconnect the A/C suction/discharge line assembly from the A/C compressor and remove and discard the O-ring seals.
    14.  
    15. Install plugs in, or tape over the suction/discharge line fitting and all of the opened condenser, accumulator and compressor ports.
    16.  

  12.  
  13. Remove the bolts that secure the A/C compressor to the mounting bracket and remove the compressor.

    Click image to see an enlarged view

    Fig. Exploded view of the compressor (4) retainers and related components-3.7L engine shown, others similar

    Exploded view of the compressor (4) retainers and related components-3.7L engine shown, others similar

    Click image to see an enlarged view

    Fig. Exploded view of the bracket (1), A/C compressor (2), bolt and washer (3), brace (4) and bolt (5)-2003 5.9L gas engine

    Exploded view of the bracket (1), A/C compressor (2), bolt and washer (3), brace (4) and bolt (5)-2003 5.9L gas engine
  14.  

To install:


NOTE
If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Refrigerant oil must be added when a accumulator, evaporator coil or condenser are replaced. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor.

  1. Install the A/C compressor onto the mounting bracket.
  2.  
  3. On the 3.7L and 4.7L gasoline engines, install and tighten the bolts in the following sequence:
    1. Install the inner front fastener #3 and hand-tighten.
    2.  
    3. Install the outer front fastener #2 and hand-tighten.
    4.  
    5. Install the rear fastener #1 and hand-tighten.
    6.  
    7. Tighten the inner front fastener #3 to 30 ft. lbs. (40 Nm).
    8.  
    9. Tighten the outer front fastener #2 to 41 ft. lbs. (55 Nm).
    10.  
    11. Tighten the rear fastener #1 to 41 ft. lbs. (55 Nm).
    12.  

  4.  
  5. For the 5.7L engine, install and tighten the bolts in the following sequence:
    1. Install the two long bolts into the mounting bracket and hand-tighten.
    2.  
    3. Install the rear bolt and hand-tighten.
    4.  
    5. Tighten the two long bolts to 30 ft. lbs. (40 Nm).
    6.  
    7. Tighten the rear bolt to 41 ft. lbs. (55 Nm).
    8.  

  6.  
  7. For the 5.9L gas engine, install and tighten the bolts in the following sequence:
    1. Install the four bolts into the mounting bracket and hand-tighten.
    2.  
    3. Tighten the four bolts to 17 ft. lbs. (24 Nm).
    4.  

  8.  
  9. Remove the tape or plugs from the opened refrigerant line fittings and compressor ports.
  10.  
  11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction and discharge line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  12.  
  13. Install the suction and discharge line fittings onto the A/C compressor:
  14.  
  15. Install the bolts or nuts (depending on engine application) that secure the suction and discharge line fittings to the A/C compressor. Tighten the bolts or nuts to 20 ft. lbs. (28 Nm).
  16.  
  17. Connect the wire harness connector to the compressor clutch coil.
  18.  
  19. Install the accessory drive belt.
  20.  
  21. Connect the compressor clutch coil wire harness connector.
  22.  
  23. Reconnect the battery negative cable.
  24.  
  25. Evacuate and charge the refrigerant system, as outlined in this section.
  26.  

 
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