Compressor HVAC: Service and Repair
REMOVAL1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM
2. DISCONNECT REFRIGERANT FROM REFRIGERATION SYSTEM
CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment
3. DRAIN ENGINE COOLANT
4. REMOVE FRONT WHEEL RH
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE FRONT FENDER APRON SEAL RH
7. REMOVE V-RIBBED BELT
8. REMOVE GENERATOR ASSEMBLY
9. DISCONNECT RADIATOR HOSE OUTLET
a. Using pliers, grip the claws of the clip and slide the clip to disconnect the radiator hose outlet.
10. REMOVE PIPING CLAMP
a. Remove the piping clamp from the No. 1 cooler refrigerant discharge hose and No. 1 cooler refrigerant suction hose.
11. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
a. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor and pulley.
b. Remove the O-ring from the No. 1 cooler refrigerant discharge hose.
NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
12. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE
a. Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor and pulley.
b. Remove the O-ring from the No. 1 cooler refrigerant suction hose.
NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
13. REMOVE COMPRESSOR AND PULLEY
a. Disconnect the connector.
b. Remove the 4 bolts, engine wire harness bracket,and the compressor and pulley.
INSTALLATION
1. ADJUST COMPRESSOR OIL LEVEL
a. When replacing the cooler compressor assembly with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the given amount of oil from the vents indicated by the arrows in the illustration before installation.
HINT: The drain bolt and washer can be reused.
Standard: AC (Oil capacity inside the new compressor and magnetic clutch: 160 + 15 cc (5.4 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing)
NOTE:
- If a new compressor and magnetic clutch is installed without removing some oil, due to the oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigeration system failure.
- If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
- Be sure to use ND-OIL 8 or equivalent for compressor oil.
2. INSTALL COMPRESSOR AND PULLEY
a. Install the compressor and pulley and the engine wire harness bracket 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 compressor and pulley.
3. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE
a. Remove the attached vinyl tape from the hose.
b. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL 8 or equivalent
c. Install the O-ring onto the No. 1 cooler refrigerant suction hose.
d. Install the No. 1 cooler refrigerant suction hose onto the compressor and magnetic clutch with the bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
4. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
a. Remove the attached vinyl tape from the hose.
b. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL 8 or equivalent
c. Install the O-ring onto the No. 1 cooler refrigerant discharge hose.
d. Install the discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
5. INSTALL PIPING CLAMP
a. Install the piping clamp to the No. 1 cooler refrigerant suction hose and No. 1 cooler refrigerant discharge hose.
6. INSTALL GENERATOR ASSEMBLY
7. INSTALL V-RIBBED BELT
8. INSTALL FRONT FENDER APRON SEAL RH
9. INSTALL RADIATOR HOSE OUTLET
a. Install the radiator hose outlet and attach the clip.
10. CONNECT BATTERY NEGATIVE TERMINAL
11. ADD ENGINE COOLANT
12. CHECK FOR ENGINE COOLANT LEAKS
NOTE: Do not turn the A/C on before charging with refrigerant. Doing so will cause the cooler compressor to work without refrigerant, resulting in overheating of the cooler compressor.
13. INSTALL ENGINE UNDER COVER RH
14. INSTALL FRONT WHEEL RH
15. CHARGE WITH REFRIGERANT
16. WARM UP ENGINE
17. CHECK FOR REFRIGERANT LEAKS