🔧 AC Compressor - Replacement

The AC compressor on your S60 is part of the sealed refrigerant system, so the refrigerant must be recovered before removal and the system must be evacuated and recharged after installation. This job is doable at home only if you have proper AC service equipment and follow the sealing, oil, and recharge steps carefully.

Difficulty Level: Advanced | Estimated Time: 4-6 hours

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⚠️ Safety & Precautions

• Refrigerant must be recovered with approved equipment before opening the AC system.
• Wear safety glasses and gloves. Refrigerant can cause frostbite and eye injury.
• Do not run the compressor dry. Incorrect oil quantity can destroy the new compressor.
• Replace all disturbed O-rings with AC-safe seals.
• Battery disconnect is recommended before working near the serpentine belt and electrical connectors.
• Keep dirt out of the open lines. Even small contamination can damage the system.

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🔧 Required Tools

You'll need the following tools for this repair:

• Socket set with ratchet and extensions
• Torx bit set
• Serpentine belt tool or long-handled wrench
• Line wrench set
• Pick tool
• Torque wrench
• Drain pan
• AC manifold gauge set
• Vacuum pump
• Refrigerant recovery machine (specialty)
• Safety glasses
• Nitrile gloves
• Jack and jack stands

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• AC compressor - Qty: 1
• AC compressor O-ring kit - Qty: 1
• AC compressor oil, specified type/amount - Qty: 1
• Serpentine belt - Qty: 1
• Refrigerant, underhood label amount - Qty: 1

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📋 Before You Begin

• Park on level ground and set the parking brake.
• Disconnect the negative battery cable before removing the belt or unplugging the compressor.
• Recover the refrigerant with approved equipment before opening any AC line.
• If the old compressor failed internally, plan to inspect the system for metal debris before reassembly.
• Keep all caps on until reassembly.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Recover refrigerant and prepare the vehicle

• Use a refrigerant recovery machine to evacuate the AC system completely.
• Disconnect the negative battery cable using a 10mm socket.
• Raise the front of the vehicle with a floor jack and support it on jack stands.

Step 2: Remove the engine undertray and belt

• Remove the lower splash shield with the correct socket set and Torx bit set.
• Relieve tension on the serpentine belt with a serpentine belt tool or long-handled wrench.
• Slip the belt off the compressor pulley and remove the belt from the engine bay.
• Take a quick belt routing photo first.

Step 3: Disconnect the compressor

• Unplug the compressor electrical connector by hand.
• Use a line wrench set to remove the refrigerant line fasteners from the compressor.
• Cap or cover both open line ends right away to keep dirt out.

Step 4: Remove the compressor

• Use the socket set with ratchet and extensions to remove the compressor mounting bolts.
• Support the compressor with one hand while removing the last bolt.
• Lower the compressor out of the engine bay carefully.

Step 5: Prepare and install the new compressor

• Drain and measure any oil from the old compressor if possible.
• Add the correct amount and type of AC oil to the new compressor.
• Install new O-rings from the AC compressor O-ring kit on the refrigerant lines.
• Use a torque wrench to install the new compressor mounting bolts. Torque to manufacturer specification.
• Reconnect the refrigerant lines and tighten them with a line wrench set. Torque to manufacturer specification.
• Reconnect the electrical connector.

Step 6: Install the belt and reassemble

• Route the new serpentine belt using the serpentine belt tool or long-handled wrench.
• Make sure the belt is seated correctly in every pulley groove.
• Reinstall the splash shield using the socket set and Torx bit set.
• Lower the vehicle off the jack stands.

Step 7: Evacuate, leak test, and recharge

• Connect the AC manifold gauge set and vacuum pump to the service ports.
• Pull a deep vacuum for at least 30-45 minutes.
• Close the valves and confirm the system holds vacuum.
• Recharge the system with the refrigerant amount listed on the underhood label.

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✅ After Repair

• Start the engine and turn the AC on MAX.
• Check for cold air, compressor engagement, and abnormal noise.
• Inspect all line connections for leaks.
• Verify both AC pressures are normal with the gauge set.
• If cooling is weak, recheck refrigerant charge and fan operation.

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💰 DIY vs Shop Cost

Shop Cost: $900-$1,600 (parts + labor)

DIY Cost: $350-$850 (parts only)

You Save: $550-$750 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 4-6 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.