Compressor HVAC: Service and Repair

Compressor And Magnetic Clutch:

COMPRESSOR AND MAGNETIC CLUTCH

REMOVAL

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. REMOVE COWL TOP VENTILATOR LOUVER RH
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.

4. REMOVE AIR CLEANER INLET COVER SUB-ASSEMBLY
5. REMOVE ENGINE ROOM SIDE COVER RH

a. Remove the 4 clips and engine room side cover.

6. REMOVE ENGINE ROOM SIDE COVER LH

a. Remove the 4 clips and engine room side cover.

7. REMOVE V-BANK COVER SUB-ASSEMBLY
8. REMOVE NO. 1 ENGINE UNDER COVER
9. REMOVE NO. 2 ENGINE UNDER COVER
10. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER
11. REMOVE FRONT WHEEL
12. REMOVE RADIATOR SUPPORT OPENING COVER
13. REMOVE FRONT BUMPER COVER
a. Remove the front bumper cover.

14. REMOVE FRONT SUSPENSION CROSSMEMBER LOWER
15. REMOVE REAR FRAME SIDE RAIL

a. Remove the 6 bolts, 4 nuts and frame rail.

16. REMOVE NO. 1 AIR CLEANER INLET
17. REMOVE RADIATOR RESERVOIR ASSEMBLY
18. REMOVE INTAKE AIR CONNECTOR PIPE
19. REMOVE FAN AND GENERATOR V BELT
20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY LH
21. REMOVE AIR CLEANER ASSEMBLY LH
22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY RH
23. REMOVE AIR CLEANER ASSEMBLY RH
24. REMOVE ENGINE ROOM ECU OUTLET DUCT

a. Remove the outlet duct.

25. REMOVE FRONT EXHAUST PIPE ASSEMBLY
a. Remove the front exhaust pipe.

26. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
27. REMOVE REAR ENGINE UNDER COVER RH
28. REMOVE FRONT STABILIZER BAR
29. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH
30. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH
31. REMOVE STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY
a. w/ VGRS:
Remove the steering sliding with shaft yoke.

b. w/o VGRS:
Remove the steering sliding with shaft yoke.

32. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
a. w/ VGRS:
Remove the No. 2 steering intermediate shaft.

b. w/o VGRS:
Remove the No. 2 steering intermediate shaft.

33. REMOVE POWER STEERING LINK ASSEMBLY
a. w/ VGRS:
Remove the power steering link.

b. w/o VGRS:
Remove the power steering link.

34. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
35. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1)
36. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

a. Remove the bolt and disconnect the cooler refrigerant suction hose from the cooler compressor.
b. Remove the O-ring from the cooler refrigerant suction hose.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

37. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

a. Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler compressor.
b. Remove the O-ring from the cooler refrigerant discharge hose.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

38. REMOVE COOLER COMPRESSOR ASSEMBLY

a. Disconnect the connector.
b. Remove the 2 bolts and 2 nuts.
c. Remove the 2 stud bolts and cooler compressor.

INSTALLATION

1. ADJUST COMPRESSOR OIL
a. When replacing the compressor and magnetic clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation.

Standard: (Oil capacity inside the new compressor and magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.) ) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing)

NOTE:
- When checking the compressor oil level, observe the A/C system's precautions.
- If a new compressor and magnetic clutch is installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure.
- If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
- Be sure to use ND-OIL 8 or equivalent for compressor oil.

2. INSTALL COOLER COMPRESSOR ASSEMBLY

a. Install the cooler compressor with the 2 stud bolts

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

b. Install the 2 bolts and 2 nuts.

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

NOTE: Tighten the nuts and bolts in the order shown in the illustration to install the cooler compressor.

c. Connect the connector.

3. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.

Compressor oil: ND-OIL 8 or equivalent

c. Install the O-ring to the cooler refrigerant suction hose.
d. Install the cooler refrigerant suction hose to the cooler compressor with the bolt.

Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf)

5. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1)
6. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
7. INSTALL POWER STEERING LINK ASSEMBLY
a. w/ VGRS:
Install the power steering link.

b. w/o VGRS:
Install the power steering link.

8. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
a. w/ VGRS:
Install the No. 2 steering intermediate shaft.

b. w/o VGRS:
Install the No. 2 steering intermediate shaft.

9. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY
a. w/ VGRS:
Install the steering sliding with shaft yoke.

b. w/o VGRS:
Install the steering sliding with shaft yoke.

10. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
11. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
12. INSTALL FRONT STABILIZER BAR
13. INSTALL REAR ENGINE UNDER COVER RH
14. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
15. INSTALL FRONT EXHAUST PIPE ASSEMBLY
a. Install the front exhaust pipe.

16. INSTALL ENGINE ROOM ECU OUTLET DUCT

a. Install the engine room outlet duct.

17. INSTALL AIR CLEANER ASSEMBLY RH
18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY RH
19. INSTALL AIR CLEANER ASSEMBLY LH
20. INSTALL AIR CLEANER CAP SUB-ASSEMBLY LH
21. INSTALL FAN AND GENERATOR V BELT
22. INSTALL INTAKE AIR CONNECTOR PIPE
23. INSTALL RADIATOR RESERVOIR ASSEMBLY
24. INSTALL NO. 1 AIR CLEANER INLET
25. INSTALL FRONT SUSPENSION CROSSMEMBER LOWER

a. Install the frame rail with the 6 bolts and 4 nuts.

Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)

26. INSTALL REAR FRAME SIDE RAIL
a. Install the frame rail with the 6 bolts and 4 nuts.

Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)

27. INSTALL FRONT BUMPER COVER
a. Install the front bumper cover.

28. INSTALL RADIATOR SUPPORT OPENING COVER
29. INSPECT FOR EXHAUST GAS LEAK
30. INSTALL FRONT WHEEL
31. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
32. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
a. Check and adjust the front wheel alignment.

33. CHECK SHIFT LEVER POSITION
34. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER

a. Install the suspension member protector with the 8 bolts.

35. INSTALL NO. 2 ENGINE UNDER COVER

a. Install the under cover with the 8 bolts.

36. INSTALL NO. 1 ENGINE UNDER COVER
37. INSTALL V-BANK COVER SUB-ASSEMBLY
38. INSTALL ENGINE ROOM SIDE COVER RH

a. Install the side cover with the 4 clips.

39. INSTALL ENGINE ROOM SIDE COVER LH

a. Install the side cover with the 4 clips.

40. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY
41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
42. INSTALL COWL TOP VENTILATOR LOUVER RH
43. ADD COMPRESSOR OIL
44. CHARGE REFRIGERANT
45. WARM UP ENGINE
46. CHECK FOR LEAKAGE OF REFRIGERANT
47. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.