Air Conditioning Compressor Replacement (LM2, 4WD)

Single Use Fasteners and Components Air Conditioning Compressor and Condenser Hose Seal - Large [2x] Air Conditioning Compressor and Condenser Hose Seal - Small [2x] Transmission Fluid Cooler Seal [2x] Removal Procedure

1. Remove the charge air cooler, condenser, fan, and radiator assembly. Charge Air Cooler, Condenser, Fan Motor, and Radiator Assembly Removal and Installation

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 1

2. Air Cleaner Outlet Front Duct Clamp (1) » Loosen [2x]
3. Air Cleaner Outlet Front Duct (2) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 2

4. Air Cleaner Nut (2) » Remove
5. Disconnect the 2 electrical connectors (5) from the mass air flow sensor and the air cleaner.
6. Remove all wiring harness retainers from the air cleaner.

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 3

7. Air Cleaner Housing Cover Bolt (1) » Remove [3x]
8. Air Cleaner Upper Housing (2) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 4

9. Air Cleaner Lower Housing (1) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 5

10. Radiator Inlet Hose Clip (1) » Disengage
11. Engine Wiring Harness Retainer (2) » Remove [2x]
12. Engine Wiring Harness Bracket Bolt (3) » Remove
13. Engine Wiring Harness Bracket (4) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 6

14. Electrical Connector (1) » Disconnect

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 7

15. Battery Positive Cable Nut (1) @ Generator » Remove
16. Generator Battery Jumper Cable (2) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 8

17. Engine Front Cover Bolt (1) » Remove
18. Engine Front Cover (2) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 9

19. Rotate the accessory drive primary belt tensioner (1) clockwise to release the drive belt tension.
20. Slide the accessory drive primary belt (2) off of the belt idler pulley and slowly release the accessory drive primary belt tensioner (1).
21. Remove the accessory drive primary belt (2).

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 10

22. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
23. Engine Wiring Harness Bracket Bolt (2) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 11

24. Engine Wiring Harness Ground Bolt (1) » Remove
25. Ground Cable (2) » Position aside
26. Disconnect electrical connectors as needed, detach retainer at intake manifold and reposition the engine wiring harness channel (3) away from the front of the engine.

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 12

27. Generator Bolt (1) » Loosen until disengaged
28. Generator Bolt (2) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 13

29. Generator (1) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 14

Note

Some components not shown for graphic clarity.

30. Electrical Connector (1) @ Air Conditioning Compressor » Disconnect [2x]

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 15

31. Air Conditioning Compressor Nut (1) » Remove
32. Air Conditioning Compressor and Condenser Hose (2) » Remove
33. Air Conditioning Compressor and Condenser Hose Seal - Large (3) » Remove and DISCARD
34. Air Conditioning Compressor and Condenser Hose Seal - Small (4) » Remove and DISCARD

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 16

35. Air Conditioning Compressor Bolt (1) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 17

36. Air Conditioning Compressor Bolt (1) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 18

37. Air Conditioning Compressor Nut (1) » Remove
38. Air Conditioning Compressor Stud (2) » Remove

Air Conditioning Compressor Replacement (LM2, 4WD) — figure 19

39. Air Conditioning Compressor (1) » Remove Installation Procedure

40. Prior to installing the air conditioning compressor perform the air conditioning compressor oil balancing procedure. Air Conditioning Compressor Oil Balancing

41. Air Conditioning Compressor (1) » Install

Caution

Refer to Fastener Caution.

3. Air Conditioning Compressor Stud (2) » Install and tighten — Fastener Specifications

4. Air Conditioning Compressor Nut (1) » Install and tighten — Fastener Specifications

5. Air Conditioning Compressor Bolt (1) » Install and tighten — Fastener Specifications

6. Air Conditioning Compressor Bolt (1) » Install and tighten — Fastener Specifications

Caution

Refer to Air Conditioning Sealing Washers Oil or Lubricant Exposure Caution.

7. Air Conditioning Compressor and Condenser Hose Seal - Large (3) » Install NEW
8. Air Conditioning Compressor and Condenser Hose Seal - Small (4) » Install NEW
9. Air Conditioning Compressor and Condenser Hose (2) » Install
10. Air Conditioning Compressor Nut (1) » Install and tighten — Fastener Specifications

Note

Some components not shown for graphic clarity.

11. Electrical Connector (1) @ Air Conditioning Compressor » Connect [2x]

12. Generator (1) » Install

13. Generator Bolt (2) » Install and tighten — Fastener Specifications

14. Generator Bolt (1) » Tighten — Fastener Specifications

15. Position the engine wiring harness channel (3) at the front of the engine, attach retainer at intake manifold, and connect electrical connectors as needed.

16. Engine Wiring Harness Bracket Bolt (2) » Install and tighten — Fastener Specifications

17. Engine Wiring Harness Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

18. Ground Cable (2) » Install

19. Engine Wiring Harness Ground Bolt (1) » Install and tighten — Fastener Specifications

20. Install the accessory drive primary belt (2) to the vehicle.

21. Rotate the accessory drive primary belt tensioner (1) clockwise.

Note

Ensure the proper routing of the accessory drive primary belt.

22. Install the accessory drive primary belt (2) around all pulleys.

23. Slowly release the accessory drive primary belt tensioner (1).

24. Engine Front Cover (2) » Install

25. Engine Front Cover Bolt (1) » Install and tighten — Fastener Specifications

26. Generator Battery Jumper Cable (2) » Install

27. Battery Positive Cable Nut (1) @ Generator » Install and tighten — Fastener Specifications

28. Electrical Connector (1) » Connect

29. Engine Wiring Harness Bracket (4) » Install

30. Engine Wiring Harness Bracket Bolt (3) » Install and tighten — Fastener Specifications

31. Engine Wiring Harness Retainer (2) » Install [2x]

32. Radiator Inlet Hose Clip (1) » Install

33. Air Cleaner Lower Housing (1) » Install

34. Air Cleaner Upper Housing (2) » Install

35. Air Cleaner Housing Cover Bolt (1) » Install and tighten [3x] — Fastener Specifications

36. INstall all wiring harness retainers to the air cleaner.

37. Air Cleaner Nut (2) » Install and tighten — Fastener Specifications

38. Connect the 2 electrical connectors (5) to the mass air flow sensor and the air cleaner.

39. Air Cleaner Outlet Front Duct (2) » Install

40. Air Cleaner Outlet Front Duct Clamp (1) » Tighten [2x] — Fastener Specifications

41. Install the charge air cooler, condenser, fan, and radiator assembly. Charge Air Cooler, Condenser, Fan Motor, and Radiator Assembly Removal and Installation