Compressor HVAC: Service and Repair
Cooler Compressor Assy:
COOLER COMPRESSOR ASSEMBLY
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the nut and disconnect the suction hose from the compressor.
b. Remove the O-ring from the suction hose.
NOTE: Keep the system free from moisture or foreign matter.
HINT: Cover the openings of the hoses with vinyl tape immediately after disconnecting.
4. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1
a. Remove the nut and disconnect the discharge hose from the compressor.
b. Remove the O-ring from the discharge hose.
NOTE: Keep the system free from moisture or foreign matter.
HINT: Cover the openings of the hoses with vinyl tape immediately after disconnecting.
5. REMOVE FAN AND GENERATOR V BELT
6. REMOVE ENGINE UNDER COVER
7. 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.
8. REMOVE MAGNETIC CLUTCH ASSEMBLY
a. Place the compressor and magnetic clutch in vise.
b. Remove the 2 screws and bracket.
c. Using SST, hold the magnetic clutch hub.
SST 07112-76060
d. Remove the bolt, magnetic clutch hub and 3 magnetic clutch washers.
HINT: The 3 washers removed in this step will be reused during installation. Keep them together as a set.
e. Using a snap ring expander, remove the snap ring and magnetic clutch rotor.
f. Disconnect the connector and remove the screw and ground wire.
g. Using a snap ring expander, remove the snap ring and magnetic clutch stator.
9. REMOVE COOLER COMPRESSOR ASSEMBLY
10. INSTALL MAGNETIC CLUTCH ASSEMBLY
a. Install the magnetic clutch stator by aligning it to the cooler compressor as shown in the illustration.
b. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
c. Install the ground wire with the screw.
d. Connect the connector.
e. Using a snap ring expander, install the magnetic clutch rotor and a new snap ring with the chamfered side facing up.
f. Install the 3 magnetic clutch washers and magnetic clutch hub.
NOTE: Reuse the 3 washers removed in step 7-(d). This is necessary to maintain the clearance between the magnetic clutch hub and magnetic clutch rotor.
g. Using SST, hold the magnetic clutch hub and install the bolt.
SST 07112-76060
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
h. Install the bracket with the 2 screws.
11. INSPECT MAGNETIC CLUTCH CLEARANCE
a. Set the dial indicator to the magnetic clutch hub.
b. Connect the battery's positive (+) lead to terminal 3 of the magnetic clutch connector and the negative (-) lead to the earth wire. Turn on and off the magnetic clutch and measure the clearance.
Standard clearance:
0.35 to 0.60 mm (0.014 to 0.024 in.)
If the measured value is out of the standard range, remove the magnetic clutch hub and adjust it with magnetic clutch washers.
NOTE: Adjustment should be performed with 3 or less magnetic clutch washers.
c. Remove the compressor from the vise.
12. INSPECT COMPRESSOR OIL
a. When replacing the compressor with new one, first gradually discharge the refrigerant gas from the service valve, and then drain the following amount of oil from the new compressor before installation.
Standard:
(Oil capacity inside new compressor: 120 + 15 cc (4.0 + 0.5 fl. oz.)) -(Remaining oil amount in the removed compressor) = (Oil amount to be removed when replacing)
NOTE:
- When checking the compressor oil level, follow the A/C system precautions.
- When installing a new compressor and magnetic clutch, the specified amount of oil must be removed from the new compressor. If the sum of the new compressor's oil and residual compressor's oil (remaining in the vehicle's pipes) is excessive, refrigerant cycle heat exchange problems will occur and the refrigerant system will not function properly.
- If the remaining oil in the removed compressor is too low, check for oil leakage.
- Be sure to use ND-OIL8 compressor oil.
13. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Temporarily install the compressor and No. 1 compressor mounting bracket with the nut.
b. Install the 3 bolts to the compressor and magnetic clutch.
Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
c. Tighten the nut.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)
d. Connect the connector.
14. INSTALL ENGINE UNDER COVER
15. INSTALL FAN AND GENERATOR V BELT
16. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1
a. Remove the vinyl tape attached to the hose.
b. Sufficiently apply compressor oil to a new O-ring and the contact surface of the discharge hose.
Compressor oil: ND-OIL 8 or equivalent
c. Connect the discharge hose to the compressor with the nut.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
17. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the vinyl tape attached to the hose.
b. Sufficiently apply compressor oil to a new O-ring and the contact surface of the suction hose.
Compressor oil: ND-OIL 8 or equivalent
c. Connect the suction hose to the compressor with the nut.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
19. PERFORM INITIALIZATION
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable the negative (-) battery terminal.
20. CHARGE REFRIGERANT
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
21. WARM UP ENGINE
22. CHECK FOR LEAKAGE OF REFRIGERANT