Compressor HVAC: Service and Repair

REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS

COMPRESSOR DRIVE BELT REMOVAL

1. Loosen bolt "A" for holding the tension pulley.
2. Loosen bolt "B" for adjustment.
3. Remove the compressor drive belt.

COMPRESSOR REMOVAL
When doing this work, be careful not to spill the compressor oil.

INSTALLATION SERVICE POINT
>A< COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the amount of oil according to the procedures described below and then install the compressor.
1. Measure the amount {x cubic.cm (x fl.oz.)} of oil within the removed compressor.
2. Drain (from the new compressor) the amount of oil calculated according to the following formula and then install then new compressor.
New compressor oil amount
120 cubic.cm - x cubic.cm = Y cubic.cm
(4.1 fl.oz - x fl.oz. = y fl.oz..)

NOTE
1. Y cubic.cm (y fl.oz.) indicates the amount of oil in the refrigerant line, the condenser, the evaporator etc.
2. When replacing the entire A/C system parts with new ones, discharge the compressor oil including A/C system parts oil from the new compressor.
Quantity:
Evaporator: 60 cubic.cm (2.0 fl.oz.)
Condenser: 15 cubic.cm (0.5 fl.oz.)
Suction hose: 10 cubic.cm (0.3 fl.oz.)
Receiver: 10 cubic.cm (0.3 fl.oz.)

INSPECTION
- Checking for heat damage of the tension pulley.
- Check for excessive play or deflection of the tension pulley.
- Check for unusual wear of the tension pulley.
- Check for hardening of the compressor drive belt.
- Check for unusual wear or abrasion of the compressor drive belt.

REFRIGERANT-TEMPERATURE SWITCH SIMPLE CHECK
When the A/C is off, check that there is continuity between the refrigerant-temperature switch terminals. If no, replace the compressor assembly.

COMPRESSOR MAGNETIC CLUTCH OPERATION INSPECTION
Connect the battery (+) terminal to the compressor side terminal and ground the battery (-) terminal to the body of the compressor. The condition is normal if the sound of the magnetic clutch (click) can be heard.

MAGNETIC CLUTCH
DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINT
NUT REMOVAL

REASSEMBLY SERVICE POINTS

>A< CLUTCH COIL INSTALLATION
When installing the clutch coil to the A/C compressor body, install so that the pin hole of the A/C compressor body and the clutch coil projection are aligned.

>B< SNAP RING INSTALLATION
Install the snap ring so that the tapered surface is to the outside.

>C< ARMATURE PLATE INSTALLATION
Align the mating mark of the crankshaft spline and the mating mark of the armature plate and then fit them together.

>D< NUT INSTALLATION
Use the special tool to hold the magnet clutch and tighten the nut in the same manner as removal.

>E< AIR GAP ADJUSTMENT
Check whether or not the air gap of the clutch is within the standard value.
Standard value: 0.40 - 0.65 mm (0.016 - 0.026 in.)

NOTE: If there is a deviation of the air gap from the standard value, make the necessary adjustment by adjusting the number of shims.