Compressor Repair Procedures

Removal

1. 1
   If the compressor is locked up, run the engine at idle and let the air conditioner operate for a few minutes, then stop the engine.
2. 2
   Disconnect the negative battery cable.
3. 3
   Recover the refrigerant using a recovery/recharging station.
4. 4
   Loosen the drive belt. (Refer to EM group - Drive Belt)
5. 5
   Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap the lines immediately after disconnecting them to prevent moisture and dirt contamination.

   

6. 6
   Disconnect the compressor clutch connector, then remove the 3 mounting bolts and the compressor (A).

   

Installation

1. 1
   Check the length of the compressor mounting bolts, then tighten them in the order A>B>C.

   

   Tightening torque: 19.6 - 24 N·m

2. 2
   Install in the reverse order of removal, and pay attention to the following items.

   A.	If installing a new compressor, drain all refrigerant oil from the removed compressor and measure its volume. Subtract the volume of drained oil from 120 cm³ (4.20 fl oz) to obtain the quantity of oil to be drained from the new compressor (through the suction port).

   B.	Replace the O-rings with new ones at each fitting and apply a thin coat of refrigerant oil before installation. Be sure to use the correct O-rings for R-134a to prevent leakage.

   C.	To avoid contamination, do not return spilled oil to the container, and never mix it with other refrigerant oils.

   D.	Immediately after use, close the container with its cap to prevent moisture absorption.

   E.	Do not spill refrigerant oil on the vehicle; it may damage the paint. If refrigerant oil gets on the paint, wipe it off immediately.

   F.	Adjust the drive belt.

   G.	Charge the system and check that it operates properly.

Inspection

1. 1
   Inspect the disc and hub assembly (A) for discoloration, flaking or other damage. If damaged, replace the clutch kit.
2. 2
   Check the pulley bearing (B) for play and rotate the pulley by hand. Replace the clutch kit with a new one if it is noisy or has excessive play/drag.

   

3. 3
   Check the operation of the magnetic clutch. Connect the compressor-side terminal to the battery (+) terminal and connect the battery (-) terminal to the compressor body. Check the magnetic clutch operating noise to determine its condition.

   

Disassembly

1. 1
   Remove the front left wheel (A).

   

2. 2
   Remove the engine side cover (A).

   

3. 3
   Remove the center bolt (A) while holding the disc and hub assembly with SST (09977-29000).

   Tightening torque: 10 ~ 15 N·m

   

4. 4
   Remove the disc and hub assembly (A) and the shim (spacer washer), taking care not to lose the shims.

   

5. 5
   Disconnect the snap ring (A) and remove the pulley (B).

   Be careful not to damage the pulley (B) and compressor during removal/installation. After removing the snap ring (A), replace it with a new one.

   

   

6. 6
   Remove the snap ring (B), then remove the field coil (C). Be careful not to damage the coil and compressor.

   

7. 7
   Reassemble the compressor clutch in the reverse order of disassembly, and pay attention to the following items:

   A.	Clean the sliding surfaces of the pulley and compressor with a non-oil solvent.

   B.	Install new snap rings and make sure they are fully seated in the groove.

   C.	Make sure the pulley rotates smoothly after reassembly.