Compressor HVAC: Service and Repair

COOLER COMPRESSOR ASSEMBLY

REPLACEMENT

1. DRAIN HFC-134A (R134A)
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

2. REMOVE GENERATOR ASSEMBLY




3. SEPARATE 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.




4. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the bolt 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.

5. REMOVE COMPRESSOR AND MAGNETIC CLUTCH




a. Disconnect the connector.
b. Remove the nut.




c. Using a E8 torx socket wrench, remove the stud bolt.




d. Remove the 3 bolts and compressor and magnetic clutch.

6. INSPECT 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 cooler compressor assembly: 120 - 135 ml) - (Remaining oil amount in the removed cooler compressor assembly) = (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 cooler compressor assembly 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 cooler compressor assembly is too small in volume, check for oil leakage.
- Be sure to use ND-OIL 8 for compressor oil.




7. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the 3 bolts, nut, stud bolt and compressor and magnetic clutch.

Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)

b. Connect the connector.




8. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the attached vinyl tape from the hose.
b. Install a new O-ring to the cooler refrigerant suction hose No.1.
c. Sufficiently apply compressor oil to the O-ring and fit surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL 8 or equivalent

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)




9. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1
a. Remove the attached vinyl tape from the hose.
b. Install a new O-ring to the cooler refrigerant discharge hose No.1.
c. Sufficiently apply compressor oil to the O-ring and fit surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL 8 or equivalent

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)

10. INSTALL GENERATOR ASSEMBLY

11. CHARGE REFRIGERANT
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
Specified amount: 650 ± 50 g (22.93 ± 1.76 oz.)

12. WARM UP ENGINE
13. INSPECT LEAKAGE OF REFRIGERANT