Compressor HVAC: Service and Repair
REMOVAL AND INSTALLATION
INSTALLATION SERVICE POINT
>A< COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the amount of oil according to the procedures described below and then install the compressor.
1. Measure the amount (X cubic cm) of oil inside the removed compressor.
2. Drain the amount of oil calculated according to the following formula from the new compressor and then install the new compressor.
New compressor oil amount: 120 cubic cm - X cubic cm = Y cubic cm
NOTE:
1. Y cubic cm indicates the amount of oil in the refrigerant line, the condenser, the cooling unit, etc.
2. When replacing the following parts at the same time as the compressor, subtract the rated oil amount of each part from Y cubic cm and discharge this amount from the new compressor.
Compressor oil: ND-OIL 8
Quantity:
Evaporator: 40 cubic cm (1.4 fl.oz)
Condenser: 40 cubic cm (1.4 fl.oz.)
Suction hose: 10 cubic cm (0.3 fl.oz.)
Receiver: 10 cubic cm (0.3 fl.oz.)
DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
CLUTCH HUB REMOVAL
1. Secure the compressor in a vise.
2. If the clutch hub cannot be pulled oft by hand, screw in a completely-threaded bolt with a thread length of mm (0.315 in.) to raise the clutch hub so it can be removed.
ROTOR ASSEMBLY REMOVAL
Use a plastic hammer to lightly tap the rotor off the shaft.
Remove the through bolt after first securing the rear housing of the compressor by placing it in a vise.
CAUTION: If the through bolt is removed without first doing so, the rear housing will become uncoupled and compressor oil will escape.
Use a flat-tip (-) screwdriver to remove the felt from the front housing.
Use a flat-tip (-) screwdriver to remove the shaft seal from the front housing.
REASSEMBLY SERVICE POINTS
>A< SHAFT SEAL INSTALLATION
1. Lubricate the shaft seal with specified compressor oil. Specified compressor oil: ND-OIL 8
2. Set the shaft seal to the front housing so that the projection side of the center ring is at the shaft seal side.
3. Use a 21 mm (0.83 in.) socket to install the shaft seal.
>B< FRONT HOUSING INSTALLATION
1. Apply specified compressor oil to the shaft.
Specified compressor oil: ND-OIL 8
2. Install the front housing, taking care not to damage the lip part of the shaft seal.
3. Mount the bolt on the shaft and then measure the shaft starting torque.
Standard value: 4.9 Nm (43 in.lbs.) or less
4. Remove the bolt from the shaft.
>C< CLUTCH COIL INSTALLATION
The clutch coil must be aligned with the pin in the compression housing.
>D< CLUTCH CLEARANCE ADJUSTMENT
1. Connect the magnetic clutch to the battery.
2. The clutch hub will be attracted to and tit closely to the rotor.
3. Use a shim(s) to adjust so that the amount of movement of the clutch hub is as described below.
Standard value: 0.35 - 0.65 mm (0.0138 - 0.0256 in.)
4. Turn the rotor by hand to confirm that it rotates freely.
INSPECTION
- Check the surface of the clutch hub for scoring or bluing.
- Check the surface of the rotor for scoring or bluing.
- Check the sealing surfaces for cracks, scratches and deformation.
- Check the front housing for cracks or scoring on the sealing surfaces.
- Check the compressor shaft for scoring.