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. REMOVE FAN AND GENERATOR V BELT
3. DISCONNECT DISCHARGE HOSE SUB-ASSY
a. Remove the nut and disconnect the discharge hose sub-assy from the compressor and magnetic clutch.
b. Remove the O-ring from the discharge hose sub-assy.
NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
4. DISCONNECT SUCTION HOSE SUB-ASSY
a. Remove the nut and disconnect the cooler refrigerant suction hose sub-assy from the compressor and magnetic clutch
b. Remove the O-ring from the cooler refrigerant suction hose sub-assy.
NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
5. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
a. Disconnect the connector.
b. Remove the nut.
c. Remove the 3 bolts, stay, compressor and compressor and magnetic clutch.
6. REMOVE MAGNET CLUTCH ASSY
a. Place the compressor and magnetic clutch in a vise.
b. Using SST remove the bolt, magnet clutch hub and magnet clutch washer.
SST 09960-10010 (09962-01000, 09963-00500)
c. Using a snap ring expander, remove the snap ring and magnet clutch rotor.
d. Remove the screw and disconnect the connector.
e. Using a snap ring expander, remove the snap ring and magnet clutch starter.
7. REMOVE COOLER COMPRESSOR BRACKET
8. REMOVE COOLER COMPRESSOR ASSY
9. INSTALL MAGNET CLUTCH ASSY
a. Fit the parts shown in the illustration and install the magnet clutch starter.
b. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
c. Install the screw and 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.
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, install the magnet clutch hub and magnet clutch washer with the bolt.
SST 09960-10010 (09962-01000, 09963-00500)
Torque: 18 N.m (183 kgf.cm, 13 ft.lbf)
10. INSPECT MAGNETIC CLUTCH CLEARANCE
a. Set the dial indicator to the magnet clutch hub.
b. Connect the battery positive lead to the terminal 1 of magnet clutch connector and the negative lead to the earth wire. Turn on and off the magnet clutch and measure the clearance.
Standard clearance:
0.35-0.60 mm (0.013 - 0.023 in.)
If the measured value is out of 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.
11. INSPECT COMPRESSOR OIL
a. When replacing the compressor and magnetic clutch with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation.
Standard:
(Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.0 + 0.5 fl. oz.) ) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing)
NOTE:
- When checking the compressor oil level, observe the precautions on the cooler removal/installation.
- Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch 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 compressor and magnetic clutch is too small in volume, check for oil leakage.
- Be sure to use ND-OIL8 for compressor oil.
12. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor and magnetic clutch and stay, compressor with the 3 bolts.
Torque: 46 N.m (469 kgf.cm, 34 ft.lbf)
b. Install the nut.
Torque: 24 N.m (245 kgf.cm, 18 ft.lbf)
c. Connect the connector.
13. INSTALL SUCTION HOSE SUB-ASSY
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor and magnetic clutch.
Compressor oil: ND-0IL8 or equivalent
c. Install a O-ring on the suction hose sub-assy.
d. Install the suction hose sub-assy on the compressor and magnetic clutch with the nut.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
14. INSTALL DISCHARGE HOSE SUB-ASSY
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor and magnetic clutch.
Compressor oil: ND-0IL8 or equivalent
c. Install a O-ring on the discharge hose sub-assy.
d. Install the discharge hose sub-assy on the compressor and magnetic clutch with the nut.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
15. INSPECT V-RIBBED BELT TENSIONER ASSY
16. INSTALL FAN AND GENERATOR V BELT
17. CHARGE REFRIGERANT
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
Specified amount: 650 ± 30 g (22.92 ± 1.06 oz.)
18. WARM UP ENGINE
19. INSPECT LEAKAGE OF REFRIGERANT