Compressor HVAC: Service and Repair
REMOVAL AND INSTALLATION
REMOVAL SERVICE POINTS
BRAKE FLUID RESERVOIR REMOVAL
Disconnect the brake fluid level sensor connector and remove the brake fluid reservoir from the compressor bracket with the hose still attached.
NOTE: Place the removed brake fluid reservoir in a place where it will not be a hindrance when removing and installing the A/C compressor and tie it with a cord.
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.
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
170 cubic cm - X cubic cm = Y cubic cm
(5.7 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 as well 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 (2.03 fl.oz)
Condenser: 15 cubic cm (0.51 fl.oz.)
Suction hose: 10 cubic cm (0.34 fl.oz.)
Receiver: 10 cubic cm (0.34 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.
DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
REFRIGERANT-TEMPERATURE SWITCH REMOVAL
1. Remove the compressor fitting block.
2. Disconnect the snap ring from the inside of the fitting block to remove the refrigerant-temperature switch.
NUT REMOVAL
Use the special tools to remove the nut.
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 at the outer side.
>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 tools to remove the nut.
>E< AIR GAP ADJUSTMENT
Check whether or not the air gap of the clutch is within the standard value.
Standard value: 0.4 - 0.65 mm (0.016 - 0.0256 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.
INSPECTION
- Check the surface of the armature for scoring or bluing.
- Check the surface of the rotor for scoring or bluing.
- Check the sealing surfaces for cracks, scratches and deformation.
- Check the front housing for cracks or scoring on the sealing surfaces.
- Check the compressor shaft for scoring.
REFRIGERANT-TEMPERATURE SWITCH CONTINUITY CHECK
1. Immerse the refrigerant-temperature switch in engine oil.
2. Use an ohmmeter to check the continuity between the terminals (1) or (2) when the engine oil has become heated.
Standard value:
CAUTION: Do not heat the oil more than necessary.
HIGH-PRESSURE RELIEF VALVE CHECK
The high-pressure relief valve is a safety feature which releases part of the refrigerant inside the system into the atmosphere when the high-pressure level exceeds 3,740 kpa (532 psi) during air conditioning operation.
Once the pressure inside the system has been reduced to 2,940 kPa(418 psi) or lower, the high-pressure relief valve closes, thus allowing continued operation.
1. If a leak is detected at section A, replace the high-pressure relief valve. The valve can be used unless there is a leak from that section.
2. If a leak is detected at section B, retighten the valve. If the leak persists after retightening the valve, replace the packing.