Compressor HVAC: Service and Repair

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 (1); (Flexible hose Ps) and high-pressure hose (2) (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. Remove compressor bell cover and alternator belt cover.
Remove bolts which secure belt covers.




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




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




7. Disconnect alternator harness.




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




10. Remove compressor.
Remove bolt which secure compressor. 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 nut 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.

Figures in table refer to the number of grooves in pulleys.
C/P : Crankshaft pulley
A/T: Alternator pulley
P/S Power steering oil pump pulley
A/C : Air conditioner compressor pulley
I/P : Idler pulley






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

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




8. Install 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.
10. Connect ground cable to negative terminal of battery.
11. Charge refrigerant.