5035663 JOHNSON BOLT

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. Plugging all lines helps to prevent fluid loss and helps to keep contaminants from entering the system.
Turn the battery disconnect switch to the OFF position.
Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure.
Illustration 1 g02321153
Typical example of a refrigerant compressor (ports may vary)
Disconnect hose assembly (1) and hose assembly (2) from refrigerant compressor (4). Refer to the Original Equipment Manufactures (OEM) for the correct procedure. Note: Cap the hose assemblies with new caps. Plugs the ports in the refrigerant compressor with new plugs.
Disconnect harness assembly (3) from refrigerant compressor (4).
Illustration 2 g02321154
Remove the alternator belt. Refer to Disassembly and Assembly, "Alternator Belts - Remove and Install" for the correct procedure.
Remove bolts (6) and bolts (7) from refrigerant compressor (4). Note: Support the weight of the refrigerant compressor on removal of the bolts.
Remove refrigerant compressor (4) from bracket (5).
Illustration 3 g02100040
Illustration 4 g02100041
If necessary, follow Step 8.a through Step 8.c in order to remove bracket (5) for the refrigerant compressor from the cylinder block.
Remove bolts (8) from bracket (5).
Remove bracket (5) from the cylinder block.
Note the position of dowels (9) in bracket (5). Installation Procedure
Illustration 5 g02100040
Illustration 6 g02100041
If necessary, follow Step 1.a through Step 1.d in order to install bracket (5) for the refrigerant compressor to the cylinder block.
Ensure that bracket (5) is clean and free from wear and damage. If necessary, replace the bracket.
Ensure that dowels (9) are free from wear and damage. If necessary, replace the dowels.
Position bracket (5) onto the cylinder block. Install bolts (8) and hand tighten the bolts.
Tighten bolts (8) to a torque of 44 N m (32 lb ft).
Illustration 7 g02321154
Position refrigerant compressor (4) onto bracket (5). Note: Support the weight of the refrigerant compressor.
Install bolts (6) and bolts (7) to refrigerant compressor (4).
Tighten bolts (6) and bolts (7) to a torque of 22 N m (195 lb in).
Install the alternator belt. Refer to Disassembly and Assembly, "Alternator Belts - Remove and Install" for the correct procedure.
Illustration 8 g02321153
Typical example of a refrigerant compressor (ports may vary)
Connect harness assembly (3) to refrigerant compressor (4).
Remove the caps from hose assemblies and remove the plugs from the ports of the refrigerant compressor. Connect hose assembly (1) and hose assembly (2) to refrigerant compressor (4). Refer to the OEM for the correct procedure.
Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct charging procedures.
Turn the battery disconnect switch to the ON position.