Compressor HVAC: Service and Repair

Compressor

REMOVAL
1. Disconnect ground cable from battery.
2. Discharge refrigerant using refrigerant recovery system.




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. Remove low-pressure hose (A) (Flexible hose Ps) and high-pressure hose (B) (Flexible hose Pd).

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




4. Compressor belt cover and generator belt cover:
Remove bolts which secure belt covers.




5. Remove alternator V-belt:
1. Loosen lock bolt on generator bracket.
2. Turn adjusting bolt and remove V-belt.




6. Remove compressor V-belt:
1. Loosen lock bolt on idler pulley.
2. Turn adjusting bolt and remove V-belt.




7. Disconnect alternator harness.
8. Disconnect compressor harness:
Disconnect compressor harness from body harness.




9. Remove lower bracket:
Remove bolts which secure lower compressor bracket.




10. Remove compressor:
1. Remove bolts which secure compressor.
2. Remove compressor from bracket.

INSTALLATION




1. Install compressor:
Install compressor on bracket.

2. Connect compressor harness.
3. Connect alternator harness.




4. Install compressor V-belt (Rear):
After adjusting belt tension, tighten tension pulley lock bolt securely.




5. Install alternator V-belt:
After adjusting V-belt tension, tighten alternator bracket lock bolt securely.







6. Check drive belt tension and adjust it if necessary by changing alternator 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. Install high-pressure hose (B) (Flexible hose Pd) and low-pressure hose (A) (Flexible hose Ps): Connect high-pressure hose (B) and low-pressure hose (A) with compressor.

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

8. 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.

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