Compressor HVAC: Service and Repair

1. Loosen the bolts "A" <4G1> or nut "A" <4G9> for holding.
2. Loosen the bolt "B" for adjustment.
3. Remove the drive belt.

SUCTION HOSE, DISCHARGE HOSE DISCONNECTION
Plug the disconnected hose and the compressor nipple not to let foreign matter get into them.

CAUTION: Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapor easily.

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 the 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 following parts at the same times as the compressor, subtract the rated oil amount of the each part from Y Cubic cm (Y fl.oz.) and discharge 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

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.