Compressor HVAC: Service and Repair
Compressor And Magnetic Clutch:
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
SST 09249-63010
3. REMOVE ALTERNATOR ASSEMBLY W/ REGULATOR
4. REMOVE GENERATOR BELT ADJUSTING BAR
a. Remove the 2 nuts, bolt and generator belt adjusting bar.
5. REMOVE COOLER REFRIGERANT DISCHARGE HOSE NO.1
a. Remove the nut 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 opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
6. REMOVE COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the nut and disconnect the cooler refrigerant suction hose No.1.
b. Remove the O-ring from the cooler refrigerant suction hose No.1.
NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
7. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
a. Disconnect the connector and clamp.
b. Remove the bolt, nut and cooler compressor bracket.
c. Remove the 3 bolts and compressor and magnetic clutch.
8. REMOVE MAGNET CLUTCH ASSEMBLY
a. Remove the screw, earth wire and cooler compressor bracket.
b. Remove the 2 bolts and the bracket.
c. Place the compressor and magnetic clutch in a vise.
NOTE: Do not get the bracket and harness caught in the vise.
d. Using SST, hold the magnet clutch hub.
SST 95047-10400
e. Remove the bolt, magnet clutch hub and magnet clutch washer.
HINT: There is no set number of magnet clutch washers since they are used for adjusting.
f. Using a snap ring expander, remove the snap ring and magnet clutch rotor.
NOTE: Do not damage the seal cover of the bearing when removing the snap ring.
g. Disconnect the connector.
h. Using a snap ring expander, remove the snap ring and magnet clutch starter.
INSTALLATION
1. INSTALL MAGNET CLUTCH ASSEMBLY
a. Matching the parts shown in the illustration and install the magnet clutch starter.
b. Using a snap ring expander, install a new snap ring with the chamfered side facing up.
NOTE: Do not damage the seal cover of the bearing when installing the snap ring.
c. 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.
NOTE:
- Do not expand the snap ring by more than 30.5 mm when installing it.
- Do not damage the seal cover of the bearing when installing the snap ring.
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, hold the magnet clutch hub and install the bolt.
SST 95047-10400
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
NOTE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub.
2. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH
a. Temporarily tighten the compressor and magnetic clutch with the bolt.
3. FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH
a. Tighten the compressor and magnetic clutch with the 3 bolts.
Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
NOTE: Tighten the bolts in the numerical order shown in the illustration to install the compressor and magnetic clutch.
b. Install the cooler compressor bracket with the bolt and nut.
Torque: Bolt (1) 25 N.m (250 kgf.cm, 18 ft.lbf)
NOTE: Tighten the bolts in the numerical order shown in the illustration to install the compressor and magnetic clutch.
c. Connect the connector.
4. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to a new O-ring and fitting surface of the compressor and magnetic clutch.
Compressor oil: ND OIL 8 or equivalent
c. Install the O-ring to the cooler refrigerant suction hose No.1.
d. Install the cooler refrigerant suction hose No.1 to the compressor and magnetic clutch with the nut.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
5. 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 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)
6. INSTALL ALTERNATOR ASSEMBLY W/ REGULATOR
7. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
SST 09249-63010
8. CHARGE REFRIGERANT
9. WARM UP ENGINE
10. INSPECT LEAKAGE OF REFRIGERANT