Compressor HVAC: Service and Repair
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1 Compressor HVAC: Service and Repair Cooler Compressor Assy REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM SST ( , , , , , ) 2. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
2 3. DISCONNECT OIL COOLER INLET HOSE NO.1 a. Using pliers, grip the claws of the clip side the clip to disconnect the oil cooler inlet hose No DISCONNECT OIL COOLER OUTLET HOSE NO.1 HINT: Disconnection of the oil cooler outlet hose No.1 is the same way as the oil cooler inlet hose No. 5. REMOVE FAN ASSY W/MOTOR a. Release the 3 clamps. b. Disconnect the connectors. c. Remove the 4 bolts and the fan assy W/ motor. 6. DISCONNECT DISCHARGE HOSE SUB-ASSY a. Remove the nut and disconnect the discharge hose sub-assy from the compressor and magnetic clutch. b. Remove the O-ring from the discharge hose sub-assy.
3 NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matters from entering. 7. DISCONNECT SUCTION HOSE SUB-ASSY a. Remove the nut and disconnect the suction hose sub-assy from the compressor and magnetic clutch. b. Remove the O-ring from the suction hose sub-assy. NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matters from entering. 8. REMOVE COMPRESSOR AND MAGNETIC CLUTCH a. Disconnect the connector. b. Release the 2 clamps and wire harness. c. Remove the 3 bolts and the cooler compressor bracket. d. Remove the 2 bolts, the stay, and the compressor and magnetic clutch. 9. REMOVE MAGNET CLUTCH ASSY
4 a. Place the compressor and magnetic clutch in a vise. b. Using SST, remove the bolt, the magnet clutch hub and the magnet clutch washer. SST ( , ) c. Using a snap ring expander, remove the snap ring and the magnet clutch rotor. d. Remove the screw and disconnect the connector. e. Using a snap ring expander, remove the snap ring and the magnet clutch starter. 10. REMOVE COOLER COMPRESSOR ASSY 11. INSTALL MAGNET CLUTCH ASSY a. Fit the parts as shown in the illustration and install the magnet clutch starter.
5 b. Using a snap ring expander, install a new snap ring with the chamfered side facing up. c. Install the screw and connect the connector. d. Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up. e. Install the magnet clutch washer and the magnet clutch hub. NOTE: Do not change the combination of the magnet clutch washers used before disassembly. f. Using SST, install the magnet clutch hub and the magnet clutch washer with the bolt. SST ( , ) Torque: 18 Nm (183 kgf.cm, 13 ft.lbf) 12. INSPECT MAGNETIC CLUTCH CLEARANCE a. Set the dial indicator to the magnet clutch hub. b. Connect the battery positive lead to the terminal 1 of the magnet clutch connector and the negative lead to the earth wire.turn on and off the magnet clutch and measure the clearance.
6 Standard clearance: 0.35 to 0.60 mm (0.013 to in.) If the measured value is not within the standard range, remove the magnet clutch hub and adjust it with the magnet clutch washers. NOTE: Adjustment can be performed with 3 or less magnet clutch washers. 13. INSPECT COMPRESSOR OIL a. When replacing the compressor and magnetic clutch with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside new compressor and magnetic clutch: cc ( fl.oz.) ) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing) NOTE: - When checking the compressor oil level, observe the precautions on the cooler removal/installation. - Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch is installed without removing some oil inside, the oil amount becomes excessive, preventing heat exchange in the refrigerant cycle and causing refrigerant failure. - If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage. - Be sure to use ND-OIL 8 for compressor oil. 14. INSTALL COMPRESSOR AND MAGNETIC CLUTCH a. Install the compressor and magnetic clutch and the stay and cooler compressor bracket with the 2 bolts. Torque: 24 Nm (245 kgf.cm, 18 ft.lbf) b. Install the 3 bolts. Torque: 24 Nm (245 kgf.cm, 18 ft.lbf) c. Connect the 2 clamps and wire harness.
7 d. Connect the connector. 15. INSTALL SUCTION HOSE SUB-ASSY a. Remove the attached vinyl tape from the hose. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent c. Install the O-ring on the suction hose sub-assy. d. Install the suction hose sub-assy on the compressor and magnetic clutch with the nut. Torque: 5.4 Nm (55 kgf.cm, 48 in.lbf) 16. INSTALL DISCHARGE HOSE SUB-ASSY a. Remove the attached vinyl tape from the hose. b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent c. Install the O-ring on the discharge hose sub-assy. d. Install the discharge hose sub-assy on the compressor and magnetic clutch with the nut. Torque: 5.4 Nm (55 kgf.cm, 48 in.lbf) 17. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO CHARGE REFRIGERANT SST ( , , , , , , , ) Specified amount: 780 ± 30 g (27.5 ± 1.06 oz.) 21. WARM UP ENGINE 22. INSPECT LEAKAGE OF REFRIGERANT
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