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. REMOVE GENERATOR ASSEMBLY
4. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1
a. Remove the bolt and disconnect the cooler refrigerant discharge hose No.1.
b. Remove the O-ring from the cooler refrigerant discharge hose No.1.
NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
5. DISCONNECT SUCTION HOSE SUB-ASSEMBLY
a. Remove the bolt and disconnect the suction hose sub-assembly.
b. Remove the O-ring from the suction hose No.1.
NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
a. Disconnect the connector.
b. Remove the 4 bolts and compressor and magnetic clutch.
7. REMOVE MAGNETIC CLUTCH ASSEMBLY
a. Remove the bolt and bracket.
b. Place the compressor and magnetic clutch in a vise.
c. Using vise pliers, hold the magnet clutch hub.
d. Remove the bolt, magnetic clutch hub and magnetic clutch washer.
e. Using a snap ring expander, remove the snap ring and magnetic clutch rotor.
f. Disconnect the connector.
g. Using a snap ring expander, remove the snap ring and magnetic clutch stator.
8. INSTALL MAGNETIC CLUTCH ASSEMBLY
a. Matching the parts shown in the illustration, install the magnetic clutch stator.
b. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
c. Connect the connector.
d. Using a snap ring expander, install the magnetic clutch rotor and a new snap ring with the chamfered side facing up.
e. Install the magnetic clutch washer and magnetic clutch hub.
NOTE: Do not change the combination of the magnetic clutch washers used before disassembly.
f. Using vise pliers, hold the magnetic clutch hub and install the bolt.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
9. INSPECT MAGNETIC CLUTCH CLEARANCE
a. Set the dial indicator to the magnetic clutch hub.
b. Connect the battery positive lead to terminal 3 of the magnetic clutch connector and the negative lead to the earth wire. Turn on and off the magnetic clutch and measure the clearance.
Standard clearance: 0.26 to 0.60 mm (0.010 to 0.024 in.)
If the measured value is out of the standard range, remove the magnetic clutch hub and adjust it with the magnetic clutch washers.
NOTE: Adjustment shall be performed with 3 or less magnetic clutch washers.
c. Remove the compressor and magnetic clutch from the vise.
10. INSPECT COMPRESSOR OIL
a. Gradually discharge the refrigerant gas from the service valve when replacing the compressor and magnetic clutch with a new one. Drain the following amount of oil from the new compressor and magnetic clutch before installation.
Standard:
(Oil capacity inside the new compressor and magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed before installation)
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, the oil amount becomes too much, 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.
11. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor and magnetic clutch with the 4 bolts.
Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
NOTE: Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.
b. Connect the connector.
12. INSTALL SUCTION HOSE SUB-ASSEMBLY
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply 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 to the suction hose sub-assembly.
d. Install the suction hose sub-assembly to the compressor and magnetic clutch with the nut .
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
13. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply 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 to the cooler refrigerant discharge hose No.1.
d. Install the cooler refrigerant discharge hose No.1 to the compressor and magnetic clutch with the nut.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
14. INSTALL GENERATOR ASSEMBLY
15. INSTALL FAN AND GENERATOR V BELT
16. CHARGE REFRIGERANT
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,07117-88060, 07117-88070, 07117-88080)
Specified amount: 450 to 550 g (15.9 to 19.4 oz.)
17. WARM UP ENGINE
18. CHECK FOR LEAKAGE OF REFRIGERANT