Removal and Installation

Compressor

REMOVAL
1) Spare tire
2) Battery negative terminal
3) Pulser (HITACHI A/C]
4) Shroud [HITACHI A/C]
5) Discharge refrigerant using manifold gauge.
(1) Fully close low-pressure valve of manifold gauge.
(2) Connect low-pressure charging hose of manifold gauge to low-pressure service valve.
(3) Open low-pressure manifold gauge valve slightly, and slowly discharge refrigerant from system.








Do not allow refrigerant to rush out. Otherwise, compressor oil will be discharged along with refrigerant.





6) Low-pressure hose (Flexible hose Ps)
a. Be careful not to lose 0-ring of low-pressure hose.
b. Plug the opening to prevent foreign matter from entering.





7) High-pressure hose (Flexible hose Pd)
a. Be careful not to lose 0-ring of high-pressure hose.
b. Plug the opening to prevent foreign matter from entering,

HITACHI A/C

8) Alternator, V-belt (front) and compressor upper bracket
9) Condenser fan ASSY
10) V-belt (rear)
11) Idler pulley ASSY
After completion of removal, temporarily assemble special nut to special bolt
12) Remove compressor and compressor lower bracket as a unit and then separate them.

PANASONIC A/C

8) Remove shroud while turning it by hand.
Be careful not to damage fan.
9) Condenser fan
10) V-belt (front)
(1) Loosen idler pulley lock nut.
(2) Loosen compressor bolts, and move compressor forward.
(3) Remove V-belt (front).
11) After disconnecting thermal protector harness connector, remove compressor.

INSTALLATION
1) Compressor

HITACHI
(1) Install compressor lower bracket onto compressor.
(2) Temporarily install the compressor sub-assembled in 1) onto engine.





Align the lower bracket and the spacer.





(3) Temporarily install compressor upper bracket onto the compressor, and secure compressor lower bracket and upper one in this order.





(4) Idler pulley ASSY
Temporarily install idler pulley ASSY on the compressor lower bracket.
(5) Installing V-belt (rear)
Place V-belt (rear) onto crankshaft pulley, power steering oil pump pulley, compressor pulley, idler pulley and water pump pulley.





PANASONIC
Temporarily place V-belt (front) onto crankshaft pulley, power steering oil pump pulley, water pump pulley, idler pulley and compressor pulley, and install compressor onto compressor bracket.











2) Adjusting the belt tension
Adjust the belt tension by changing the idler pulley position.





3) Alternator and V-belt (front) [HITACHI A/C]
(1) Temporarily install alternator on compressor bracket.
(2) Place the V-belt (front) onto crankshaft pulley, power steering oil pump pulley, compressor pulley, alternator pulley and water pump pulley and adjust the belt tension by changing the alternator position.





a. Ensure that the V-belt is aligned correctly. It it is not, check for loose bolts.
b. The V-belt should not be too tight or too loose. A belt which is too tight may break bearing or cause gas to leak from the shaft seal. A belt which is too loose slips, there-by causing the belt cut.
c. After completing the compressor installation and testing the system operation, check and adjust the tension of both V-belts again.








4) Connect the compressor harness and body harness.





5) Condenser fan ASSY
(1) Assemble fan drive and condenser fan.
(2) Install condenser fan ASSY onto water pump pulley.

6) High-pressure hose (Flexible hose Pd)
Connect high-pressure hose with compressor.

Tightening torque:

HITACHI
18 - 31 N-m (1.8 - 3.2 kg-m, 13 - 23 ft-lb)

PANASONIC
18 - 31 N-m (1.8 - 3.2 kg.m, 13 - 23 ft-lb)

Be sure to apply compressor oil to the periphery of 0-ring.









7) Low-pressure hose (Flexible hose Ps)
Connect low-pressure hose with compressor.

Tightening torque:
HITACHI
18 - 31 N-m (1.8-3.2 kg.m, 13 - 23 ft-lb)
PANASONIC
18 - 31 N-m (1.8 - 3.2 kg.m, 13 - 23 ft-lb)

Be sure to apply compressor oil to the periphery of 0-ring.





8) Shroud
Install shroud on radiator member.

Tightening torque:
5.4 - 9.3 N-m (0.55-0.95 kg-m, 4.0 - 6.9 ft-lb)








9) Pulser
(1) Install pulser onto the compressor. (HITACHI A/C ONLY)
(2) Connect pulser connector.

Be sure to provide a specified clearance between the pulser's sending portion and compressor clutch.





HITACHI

10) Battery negative terminal
11) Charging refrigerant
12) Spare tire

CLUTCH ASSEMBLY OPERATION TEST
1) Rotate the rotor with a hand. No abnormal noise nor play must be noted.
2) Apply a voltage of 12V (battery voltage) across the coil terminals. The clutch plate must be attracted.
3) Make sure the armature gap is 0.5 to 0.8 mm (0.020 to 0.031 in).

BREAK-IN TEST
After completing the above-mentioned tests, install the compressor to the refrigerant cycle unit (if unavailable, actual vehicle), and perform break-in operation for 30 minutes under the following conditions:

Conditions:
Rotating speed: 1,800 rpm
High pressure: 1,324 ± 98 kPa
(13.5 ± 1 kg/cm2, 192 ± 14 psi)
Low pressure: 147 - 196 kPa
(1.5 - 2 kg/cm2, 21 - 28 psi)