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 (A) and high-pressure hose (B).

CAUTION:
- Be careful not to lose O-ring of low-pressure hose.
- Plug the opening to prevent foreign matter from entering.




4. Compressor belt cover and generator belt cover: Remove bolts which secure belt covers.




5. Remove generator V-belt:
1. Loosen lock bolt (A) on generator bracket.
2. Turn adjusting bolt (B) and remove V-belt.




6. Remove compressor V-belt:
1. Loosen lock nut (A) on idler pulley.
2. Turn adjusting bolt (B) and remove V-belt.




7. Disconnect generator harness.

8. Disconnect compressor harness:
Disconnect compressor harness from body harness.




9. Remove lower bracket:
Remove bolts which secure lower compressor bracket.




10. Remove compressor:
1. Remove bolts which secure compressor.
2. Remove compressor from bracket.

INSTALLATION




1. Install compressor:
Install compressor on bracket.




2. Install lower bracket.
3. Connect compressor harness.
4. Connect generator harness.




5. Install compressor V-belt (Rear):
After adjusting belt tension, tighten tension pulley lock nut (A) securely.




6. Install generator V-belt:
After adjusting V-belt tension, tighten generator bracket lock bolt (A) securely.




7. Check drive belt tension and adjust it if necessary by changing generator position and/or idler pulley position.

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.




8. Install high-pressure hose (B) and low-pressure hose (A).

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

9. Install belt cover.

CAUTION:
- After installing belt cover, make sure it is not misaligned or twisted.
- After installing belt cover, check the clearance between pulley and belt cover.

10. Connect ground cable to negative terminal of battery.
11. Charging refrigerant.