Compressor HVAC: Service and Repair

1. Loosen nut "A" for holding the tension pulley.
2. Loosen bolt "B" for adjustment.
3. Remove the generator and 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
170 - 190 Cubic cm - X Cubic cm = Y Cubic cm
(5.1 fl.oz. - x fl.oz. = V 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.

DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINTS

NUT REMOVAL

DISASSEMBLY 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

1. Install the nut.

2. Check whether or not the air gap of the clutch is within the standard value.
Standard value: 0.4 - 0.65 mm (0.02-0.03 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
Check that there is continuity between connector terminals 1 and 2.

REVOLUTION PICK UP SENSOR CHECK
Check that the resistance between connector terminals 3 and 4 is in the standard value range.
Standard value: 405 ± 35 Ohms (at 20°C)