Compressor HVAC: Service and Repair

Removal / Installation
1. Discharge the refrigerant from the system.
2. Remove the splash shield. (Front RH).
3. Remove the A/C drive belt.
4. Disconnect the magnetic clutch connector.
5. Remove in the order shown in the figure. Do not allow compressor oil to spill. Immediately plug all open fittings to keep moisture out of the system.
6. Install in the reverse order of removal.
7. Charge the system and test its performance.

NOTE: Follow the procedure below when replacing the A/C compressor with a new one:
1. Measure the amount of compressor oil remaining in the old A/C compressor.
2. Remove the following amount of compressor oil from the new A/C compressor.

Compressor oil to be removed
= 175 ml (175 cc, 5.92 fl oz) - [compressor oil from old A/C compressor + 10-20 ml (10-20 cc, 0.4-0.6 fl oz)]

Disassembly / Assembly
1. Remove the magnetic clutch.




2. Before disassembling the A/C compressor, clean it with kerosene to remove foreign objects and dust. Allow it to dry completely.




3. Disassemble in the order shown in the figure.
4. Clean the sealing surfaces of the rear case and A/C compressor body by using an oil stone after disassembly.
5. Remove any oil from the bolt holes.
6. Assemble in the reverse order of disassembly.

Disassembly Note




Thermal Protector
Remove the snap ring and push the protector out from its back side to remove it. Do not pull on the wiring harness.

Assembly Notes




1. Make sure the O-rings are free from foreign material. Apply compressor oil to the O-rings and fit them into the grooves securely.
2. Check for continuity between the Thermal Protector terminals.
3. Install the snap ring so that its chamfered edge faces the thermal protector. Make sure the snap ring is seated securely in its groove.




4. Install the thermal protector so that its two lead wire outlet sections are horizontal, as shown on the left.




5. Replace the O-ring and gasket with new ones. Apply compressor oil to the gasket and assemble them. Make sure the top side of the gasket faces upward.




6. Carefully install the head cover on the A/C compressor. Tighten socket head bolts A, and then tighten bolts B in a diagonal manner.




7. Tighten the pressure relief valve by hand and then tighten it to the specified torque.