Compressor HVAC: Service and Repair
Cooler Compressor Assy:
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the bolt and disconnect the cooler refrigerant suction hose No.1 from the w/ pulley compressor assembly.
b. Remove the O-ring from the cooler refrigerant suction hose No.1.
NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
3. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1
a. Remove the bolt and disconnect the cooler refrigerant discharge hose No.1 from the w/ pulley compressor assembly.
b. Remove the O-ring from the cooler refrigerant discharge hose No.1.
NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE FAN AND GENERATOR V BELT
6. REMOVE W/ MAGNETIC CLUTCH COMPRESSOR ASSEMBLY
a. Disconnect the connector.
b. Remove the 4 bolts and the w/ magnetic clutch compressor assembly.
7. REMOVE MAGNET CLUTCH ASSEMBLY
a. Using SST, hold the magnet clutch hub.
SST 95047-10400
b. Remove the bolt, magnet clutch hub and magnet clutch washer.
HINT: There is no set number of magnet clutch washers since they are used for adjusting.
c. Using a snap ring expander, remove the snap ring and magnet clutch rotor.
NOTE: Do not damage the seal cover of the bearing when removing the snap ring.
d. Disconnect the connector.
e. Using a snap ring expander, remove the snap ring and magnet clutch starter.
8. INSTALL MAGNET CLUTCH ASSEMBLY
a. Matching the parts shown in the illustration, install the magnet clutch starter.
b. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
NOTE: Do not damage the seal cover of the bearing when installing the snap ring.
c. Connect the connector.
d. Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up.
NOTE:
- Do not expand the snap ring by more than 30.5 mm (1.2 in.) when installing it.
- Do not damage the seal cover of the bearing when installing the snap ring.
e. Install the magnet clutch washer and magnet clutch hub.
NOTE: Do not change the combination of the magnet clutch washers used before disassembly.
f. Using SST, hold the magnet clutch hub and install the bolt.
SST 95047-10400
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
NOTE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub.
9. INSPECT MAGNETIC CLUTCH CLEARANCE
a. Set the dial indicator to the magnet clutch hub.
b. Connect the battery positive lead to the terminal of the magnet clutch connector and the negative lead to the earth wire. Turn the magnet clutch on and off and measure the clearance.
Standard clearance: 0.35 to 0.60 mm (0.014 to 0.023 in.)
If the measured value is not within the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers.
NOTE: Adjustment shall be performed with 3 or less magnet clutch washers.
c. Remove the compressor and magnetic clutch from the vise.
10. ADJUST COMPRESSOR OIL
a. When replacing the w/ pulley compressor assembly with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new w/ pulley compressor assembly before installation.
Standard:
(Oil capacity inside new w/ pulley compressor assembly: 140 + 15 cc (4.7 + 0.5 fl. oz.) ) - (Remaining oil amount in the removed w/ pulley compressor assembly) = (Oil amount to be removed when replacing)
NOTE:
- When checking the compressor oil level, observe the precautions on the cooler removal/installation.
- Since compressor oil remains in the pipes of the vehicle, if a new w/ pulley compressor assembly is installed without removing some oil inside, the oil amount becomes excessive, preventing heat exchange in the refrigerant cycle and causing refrigerant failure.
- If the remaining oil in the removed w/ pulley compressor assembly is too small in volume, check for oil leakage.
- Be sure to use ND-OIL 8 for compressor oil.
11. INSTALL W/ MAGNETIC CLUTCH COMPRESSOR ASSEMBLY
a. Install the w/ magnetic clutch compressor assembly with the 4 bolts.
Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
NOTE: Tighten the bolts in the order shown in the illustration to install the w/ magnetic clutch compressor assembly.
b. Connect the connector.
12. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the w/ magnetic clutch compressor assembly.
Compressor oil: ND-OIL 8 or equivalent
c. Install the O-ring on the cooler refrigerant discharge hose No.1.
d. Install the cooler refrigerant discharge hose No.1 on the w/ magnetic clutch compressor assembly with the bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
13. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the w/ magnetic clutch compressor assembly.
Compressor oil: ND-OIL 8 or equivalent
c. Install the O-ring on the cooler refrigerant suction hose No.1.
d. Install the cooler refrigerant suction hose No.1 on the w/ magnetic clutch compressor assembly with the bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
14. INSTALL FAN AND GENERATOR V BELT
15. ADJUST FAN AND GENERATOR V BELT
16. CHARGE REFRIGERANT
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
Specified amount: 400 ± 30 g (14.1 ± 1.1 oz.)
17. WARM UP ENGINE
18. CHECK FOR LEAKAGE OF REFRIGERANT