Compressor HVAC: Service and Repair
Cooler Compressor Assy:
REPLACEMENT
1. DRAIN REFRIGERANT
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the nut, disconnect the cooler refrigerant suction hose No.1 from the compressor and magnetic clutch.
b. Remove the O-ring from the cooler refrigerant suction hose No.1.
NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.
3. SEPARATE COOLER REFRIGERANT DISCHARGE HOSE NO.1
a. Remove the nut, disconnect the cooler refrigerant discharge hose No.1 from the compressor and magnetic clutch.
b. Remove the O-ring from the cooler refrigerant discharge hose No.1.
NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.
4. REMOVE FAN AND GENERATOR V BELT
5. REMOVE ENGINE UNDER COVER
6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
a. Disconnect the connector.
b. Remove the 3 bolts.
c. Remove the nut, No.1 compressor mounting bracket and compressor and magnetic clutch.
7. REMOVE MAGNET CLUTCH ASSY
a. Place the compressor and magnetic clutch in vise.
b. Remove the 2 screws and bracket.
c. Using SST, hold the magnet clutch hub.
SST 07112-76060
d. Remove the bolt, magnet clutch hub and 3 magnet clutch washers.
e. Using a snap ring expander, remove the snap ring and magnet clutch rotor.
f. Disconnect the connector, remove the screw and earth wire.
g. Using a snap ring expander, remove the snap ring and magnet clutch stator.
8. REMOVE COOLER COMPRESSOR ASSY
9. INSTALL MAGNET CLUTCH ASSY
a.Matching the parts shown in the illustration, install the magnet clutch stator.
b. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
c. Install the earth wire with the screw.
d. Connect the connector.
e. Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up.
f. Install the magnet clutch washer and magnet clutch hub.
NOTE: Do not change the combination of the magnet clutch washers used before disassembly.
g. Using SST, hold the magnet clutch hub and install the bolt
SST 07112-76060
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
h. Install the 2 screws and bracket.
10. INSPECT MAGNETIC CLUTCH CLEARANCE
a. Set the dial indicator to the magnet clutch hub.
b. Connect the battery positive lead to the terminal 3 of magnet clutch connector and the negative lead to the earth wire. Turn on and off the magnet clutch and measure the clearance.
Standard clearance: 0.35 - 0.60 mm (0.014 - 0.024 in.)
If the measured value is out of the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers.
NOTE: Adjustment shall be performed with 3 or less magnet clutch washers.
c. Remove the compressor and magnetic clutch from the vise.
11. INSPECT COMPRESSOR OIL
a. When replacing the compressor and magnetic clutch with 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: 120 - 135 ml) (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 too much, 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.
12. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor and magnetic clutch and No.1 compressor mounting bracket.
b. Temporarily tighten the nut.
c. Install the 3 bolts to the compressor and magnetic clutch.
Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
d. Tighten the nut.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)
e. Connect the connector.
13. INSTALL ENGINE UNDER COVER
14. INSTALL FAN AND GENERATOR V BELT
15. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1
a. Remove the attached vinyl tape from the hose.
b. Lubricate a new O-ring with compressor oil, install them to the cooler refrigerant discharge hose No.1.
Compressor oil: ND-OIL 8 or equivalent
c. Connect the cooler refrigerant discharge hose No.1 to the compressor and magnetic clutch, install the nut.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
16. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the attached vinyl tape from the hose.
b. Lubricate a new O-ring with compressor oil, install them to the cooler refrigerant suction hose No.1.
Compressor oil: ND-OIL 8 or equivalent
c. Connect the cooler refrigerant suction hose No.1 to the compressor and magnetic clutch, install the nut.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
17. CHARGE REFRIGERANT
SST 07117-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
18. WARM UP ENGINE
19. INSPECT LEAKAGE OF REFRIGERANT