Compressor HVAC: Service and Repair

Compressor And Pulley (For 3UZ-FE):

COMPRESSOR AND PULLEY (for 3UZ-FE)

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTE: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE COOL AIR INTAKE DUCT SEAL
3. REMOVE ENGINE ROOM SIDE COVER LH
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
5. REMOVE NO. 1 AIR CLEANER INLET
6. REMOVE V-BANK COVER
7. REMOVE FAN AND GENERATOR V BELT
8. REMOVE ENGINE UNDER COVER

9. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

a. Remove the bolt and disconnect the suction hose from the compressor.
b. Remove the O-ring from the suction hose.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

10. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

a. Remove the bolt and disconnect the discharge hose from the compressor.
b. Remove the O-ring from the discharge hose.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

11. REMOVE OIL FILTER
a. Remove the oil filter.

12. REMOVE COMPRESSOR ASSEMBLY

a. Disconnect the connector.
b. Remove the 3 bolts, nut and bracket.
c. Remove the compressor.

INSTALLATION

1. ADJUST COMPRESSOR OIL
a. When replacing the compressor and magnetic clutch with a new one, after gradually discharging the refrigerant gas from the service valve, drain the following volume of oil from the new compressor and magnetic clutch before installation.

Standard: (Oil capacity inside a new compressor and magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing the compressor)

NOTE:
- When checking the compressor oil level, observe the precautions in the cooler removal/installation.
- If a new compressor and magnetic clutch are installed without removing some oil remaining in the pipes of the vehicle, the oil amount becomes excessive. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure.
- If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
- Be sure to use ND-OIL 8 for compressor oil.

2. INSTALL COMPRESSOR ASSEMBLY

a. Hang the compressor bracket onto the fan bracket and temporarily install the compressor with the bolt.

b. Install the compressor with the 3 bolts, nut and bracket.

Torque:
49 N.m (500 kgf.cm, 36 ft.lbf) for bolt
29.4 N.m (300 kgf.cm, 22 ft.lbf) for nut

NOTE: Tighten the bolts in the order given in the illustration to install the compressor.

3. INSTALL OIL FILTER
a. Install the oil filter.

4. INSTALL DISCHARGE HOSE SUB-ASSEMBLY

a. Remove the vinyl tape attached to the hose.
b. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor.

Compressor oil: ND-OIL 8 or equivalent

c. Install the O-ring on the suction hose.
d. Install the suction hose on the compressor with the bolt.

Torque: 9.8 N.m (100 kgf.cm, 7 in.lbf)

6. INSTALL ENGINE UNDER COVER
7. INSTALL FAN AND GENERATOR V BELT
8. INSTALL V-BANK COVER
9. INSTALL NO. 1 AIR CLEANER INLET
10. INSTALL ENGINE ROOM SIDE COVER LH
11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
12. CHARGE REFRIGERANT
13. INSTALL COOL AIR INTAKE DUCT SEAL
14. WARM UP ENGINE
15. CHECK FOR LEAKAGE OF REFRIGERANT

16. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.