Removal and Installation

REMOVAL




1. Disconnect ground cable from battery.
2. 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.

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




3. Low-pressure hose (1) (Flexible hose Ps)

CAUTION:
- Be careful not to lose O-ring of low-pressure hose.
- Plug the opening to prevent foreign matter from entering.




4. High-pressure hose (2) (Flexible hose Pd)

CAUTION:
- Be careful not to lose O-ring of high-pressure hose.
- Plug the opening to prevent foreign matter from entering.




5. Compressor belt cover and generator belt cover Remove bolts which secure belt covers.




6. Generator V-belt
Loosen lock bolt on generator bracket. Turn adjusting bolt and remove V-belt.




7. Compressor V-belt
Loosen lock bolt on idler pulley. Turn adjusting bolt and remove V-belt.




8. Generator harness




9. Compressor harness
Disconnect compressor harness from body harness.
10. Lower bracket
Remove bolts which secure lower compressor bracket.




11. Compressor Remove bolts which secure compressor. Remove compressor from bracket.

INSTALLATION




1. Compressor
Install compressor on bracket.
2. Compressor harness
3. Generator harness
4. Compressor V-belt (Rear)
After adjusting belt tension, tighten tension pulley lock bolt securely.




5. Generator V-belt
After adjusting V-belt tension, tighten generator bracket lock bolt securely.




6. Check drive belt tension and adjust it if necessary by changing generator position and/or idler pulley position.






CAUTION:
- Ensure that the V-belt is aligned correctly. If it is not, check for loose bolts.
- 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, thereby causing the belt cut.
- After completing the compressor installation and testing the system operation, check and adjust the tension of both V-belts again.




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

CAUTION: Be sure to apply compressor oil to the periphery of O-ring.




8. Low-pressure hose (1) (Flexible hose Ps) Connect low-pressure hose with compressor.

CAUTION: Be sure to apply compressor oil to the periphery of O-ring.

9. Install belt cover.

CAUTION:
- After installing belt cover, make sure it is not misaligned or twisted.
- After installing belt cover, check the clearance between pulley and belt cover.

10. Connect ground cable to negative terminal of battery.
11. Charging refrigerant.