Compressor HVAC: Service and Repair

1. Loosen nut "A" for holding the tension pulley.
2. Loosen bolt "B" for adjustment.
3. Loosen the power steering oil pump fixing bolt (2.0L engines).
4. Remove the compressor drive belt.

COMPRESSOR REMOVAL
When doing this work, be careful not to spill the compressor oil.

INSTALLATION SERVICE POINTS

>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 (x fl.oz.)) of oil within the removed compressor.
2. Drain (from the new compressor) the amount of oil calculated according to the following formula and then install then new compressor.
New compressor oil amount
100 cubic cm - X cubic cm = Y cubic cm
(3.4 fl.oz. - x fl.oz. = y fl.oz.)

NOTE
1. Y cubic cm (y fl.oz.) indicates the amount of oil in the refrigerant line, the condenser, the evaporator etc.
2. When replacing the following parts as well as the compressor, subtract the rated oil amount of the each part from Y cubic cm (Y fl.oz.) and discharge from the new compressor.

Quantity
Evaporator: 40 cubic cm (1.35 fl.oz.)
Condenser: 40 cubic cm (1.35 fl.oz)
Suction hose: 10 cubic cm (0.34 fl.oz.)
Receiver: 10 cubic cm (0.34 fl.oz.)

INSPECTION
- Checking for heat damage of the tension pulley.
- Check for excessive play or deflection of the tension pulley.
- Check for unusual wear of the tension pulley.
- Check for hardening of the compressor drive belt.
- Check for unusual wear or abrasion of the compressor drive belt.

DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINT

CLUTCH HUB REMOVAL
1. Remove the clutch hub mounting bolt.
2. Tighten a 10 mm diameter (0.39 in.) bolt into the bolt hole of the clutch hub to remove the serration assembly of the shaft and the clutch hub.

REASSEMBLY SERVICE POINTS

>A< SHAFT SEAL INSTALLATION
Use a 21 mm (0.83 in.) socket to install the shaft seal so that the O-ring assembly side is facing the front housing.

>B< FELT, FELT HOLDER INSTALLATION
After installing the felt in the felt holder, install them to the front housing using a 14 mm (0.55 in.) deep socket.

>C< FRONT HOUSING INSTALLATION

1. Apply compressor oil to the shaft.
Compressor oil: ND-OIL 8
2. Install the front housing without damaging the shaft seal lip.

3. After installing the front housing, install the clutch hub mounting bolt to the shaft and check that the breakaway torque is within the specified torque value.
Breakaway torque: 5 Nm (4 ft.lbs.) or less

>D< CLUTCH COIL INSTALLATION
Set the clutch coil pin in the compressor housing notch and install the clutch coil.

>E< AIR GAP ADJUSTMENT
Apply battery voltage to the magnetic clutch and check that the air gap is within the standard value. If the air gap is outside the standard value, adjust with a shim.
Standard value: 0.35 - 0.65 mm (0.0138 - 0.0256 in.)

NOTE: If there is a deviation of the air gap from the standard value, adjust the number of shims.

INSPECTION
- Check the surface of the armature 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.

REVOLUTION PICKUP SENSOR CHECK
Check the resistance value between terminals (1) and (2).
Standard value: 185 ohms [when at 20° C (68° F)]

HIGH-PRESSURE RELIEF VALVE CHECK
The high-pressure relief valve is a safety feature which re leases part of the refrigerant inside the system into the atmosphere when the high-pressure level exceeds 3,740 kPa (532 psi) during air conditioning operation.
Once the pressure inside the system has been reduced to 2,940 kPa(418 psi) or lower, the high-pressure relief valve closes, thus allowing continued operation.
1. If a leak is detected at section A, replace the high-pressure relief valve. The valve can be used unless there is a leak from that section.
2. If a leak is detected at section B, retighten the valve. If the leak persists after retightening the valve, replace the packing.