Compressor HVAC: Service and Repair
REMOVAL1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
5. REMOVE ENGINE UNDER COVER
6. REMOVE DRIVE BELT
7. GS400:
DISCONNECT DISCHARGE HOSE
Remove the nut and disconnect the discharge hose.
NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system.
8. GS400:
REMOVE SUCTION HOSE
Remove the nut, bolt and suction hose.
NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system.
9. GS300:
DISCONNECT DISCHARGE AND SUCTION HOSES
Remove the 2 nut and disconnect the both hoses.
NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system.
10. GS300:
REMOVE 2 PS PUMP SET BOLTS
11. GS300:
REMOVE COMPRESSOR
a. Remove the bolt and PS pump bracket.
b. Remove the 2 bolts and compressor bracket.
c. Disconnect the connector.
d. Remove the nut and 3 bolts.
e. Using a torx socket (E10), remove the stud bolt and compressor.
12. GS400:
REMOVE COMPRESSOR
a. Disconnect the connector.
b. Remove the nut, bolt and compressor stay.
c. Remove the 2 bolts and compressor.
INSTALLATION
1. GS400:
INSTALL COMPRESSOR
a. Install the compressor with the 2 bolts temporarily.
b. Install the compressor stay with the bolt and nut temporarily.
c. Tighten the nut and 3 bolts.
Torque:
Bolt: 49 Nm (500 kg.cm, 36 ft.lb)
Nut: 29 Nm (300 kg.cm, 22 ft.lb)
d. Connect the connector.
2. GS300:
INSTALL COMPRESSOR
a. Install the compressor with the stud bolt.
Torque: 52 Nm (530 kg.cm, 38 ft.lb)
b. Install the 3 bolts and nut.
Torque:
Bolt: 52 Nm (530 kg.cm, 38 ft.lb)
Nut: 26 Nm (265 kg.cm, 19 fl.lb)
c. Connect the connector.
d. Install the compressor bracket with the 2 bolts.
Torque: 52 Nm (530 kg.cm, 38 fl.lb)
e. Install the PS pump bracket with the 2 bolts.
Torque: 52 Nm (530 kg.cm, 38 fl.lb)
3. GS300
INSTALL 2 PS PUMP SET BOLTS
Torque: 58 Nm (590 kg.cm, 43 ft.lb)
4. GS300:
CONNECT DISCHARGE AND SUCTION HOSES
Connect the both hoses with the 2 nut.
Torque: 10 Nm (100 kg.cm, 7 ft.lb)
NOTE: Hose should be connected immediately after the caps have been removed.
HINT: Lubricate 2 new O-rings with compressor oil and install them to the hoses.
5. GS400:
CONNECT DISCHARGE HOSE
Connect the discharge hose with the nut.
Torque: 10 Nm (100 kg.cm, 7 ft.lb)
NOTE: Hose should be connected immediately after the cap have been removed.
HINT: Lubricate a new O-ring with compressor oil and install them to the hose.
6. GS400:
INSTALL SUCTION HOSE
Install the suction hose with the bolt and nut.
Torque: 10 Nm (100 kg.cm, 7 ft.lb)
NOTE: Hose should be connected immediately after the caps have been removed.
HINT: Lubricate 2 new O-rings with compressor oil and install them to the hose.
7. INSTALL DRIVE BELT
8. INSPECT DRIVE BELT TENSION
9. INSTALL ENGINE UNDER COVER
10. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTER
11. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
12. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant.
If there is leakage, check the tightening torque at the joints.
13. INSPECT A/C OPERATION