Compressor HVAC: Service and Repair
Cooler Compressor Assy:
COOLER COMPRESSOR ASSEMBLY (ZZ E/G Series)
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. REMOVE ENGINE UNDER COVER RH (2ZZ-GE ENGINE TYPE)
3. REMOVE CYLINDER HEAD COVER NO.2 (2ZZ-GE ENGINE TYPE)
4. REMOVE WIRE HARNESS PROTECTOR (2ZZ-GE ENGINE TYPE)
5. REMOVE AIR SWITCHING VALVE ASSEMBLY (2ZZ-GE ENGINE TYPE)
6. REMOVE ENGINE UNDER COVER RH (1ZZ-FE ENGINE TYPE)
7. DISCONNECT SUCTION HOSE SUB-ASSEMBLY
a. Remove the bolt and disconnect the suction hose sub-assembly from the compressor and magnetic clutch.
b. Remove the O-ring from the suction hose sub-assembly.
NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
8. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY
a. Remove the bolt and disconnect the discharge hose sub-assembly from the compressor and magnetic clutch.
b. Remove the O-ring from the discharge hose sub-assembly.
NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
9. REMOVE FAN AND GENERATOR V BELT (2ZZ-GE ENGINE TYPE)
10. REMOVE FAN AND GENERATOR V BELT (1ZZ-FE ENGINE TYPE)
11. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
a. Disconnect the connector.
b. Remove the 3 bolts and the compressor and magnetic clutch.
12. REMOVE MAGNET CLUTCH ASSEMBLY
a. Place the compressor and magnetic clutch in vise.
b. Using SST remove the bolt.
SST 95047-10400
c. Remove the magnet clutch hub and magnet clutch washers.
HINT: There is no set number of magnet clutch washers since they are used for adjustment.
d. Using a snap ring expander, remove the snap ring and magnet clutch rotor.
e. Remove the screw, disconnect the connector.
f. Using a snap ring expander, remove the snap ring and magnet clutch stator.
13. INSTALL MAGNET CLUTCH ASSEMBLY
a. Matching the parts shown in the illustration, install the magnet clutch stator.
b. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
c. Install the screw, 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, secure the magnet clutch hub and tighten it with the bolt.
SST 95047-10400
Torque: 18 N.m (183 kgf.cm, 13 ft.lbf)
NOTE: Ensure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub.
14. INSPECT MAGNETIC CLUTCH CLEARANCE
a. Set the dial indicator to the magnet clutch hub.
b. Connect the battery positive lead to the 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 to 0.60 mm (0.013 to 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.
15. ADJUST COMPRESSOR OIL
a. When replacing the compressor and magnetic clutch with 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 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 or equivalent for compressor oil.
16. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor and magnetic clutch with the 3 bolts.
Toque: 29 N.m (295 kgf.cm, 21 ft.lbf)
NOTE: Tighten the bolts in following order shown in the illustration to install the compressor and magnetic clutch.
b. Connect the connector.
17. INSTALL DISCHARGE HOSE SUB-ASSEMBLY
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL8 or equivalent
c. Install a O-ring to the discharge hose sub-assembly.
d. Install the discharge hose sub-assembly to the compressor and magnetic clutch with the bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
18. INSTALL SUCTION HOSE SUB-ASSEMBLY
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL8 or equivalent
c. Install a O-ring to the suction hose sub-assembly.
d. Install the suction hose sub-assembly to the compressor and magnetic clutch with the bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
19. INSTALL AIR SWITCHING VALVE ASSEMBLY (2ZZ-GE ENGINE TYPE)
20. INSTALL CYLINDER HEAD COVER NO.2 (2ZZ-GE ENGINE TYPE)
21. CHARGE REFRIGERANT
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080), 07117-48130, 07117-48140
Specified amount: 480 ± 30 g (16.9 ± 1.06 oz.)
22. WARM UP ENGINE
23. INSPECT LEAKAGE OF REFRIGERANT