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 avoid moisture and dust contamination.
If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off.
Disconnect the negative cable from the battery.
Recover the refrigerant with a recovery/charging station*.
Loosen the drive belt.
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 avoid moisture and dust contamination.
Disconnect the compressor clutch connector (B), and then remove 3 mounting bolts and the compressor.
Make sure of the length of compressor mounting bolts, and then tighten it A→B→C order.
Torque:
20.0~32.9N.m (2.04~3.36kgf.m, 14.7~24.3lb-ft)
Install in the reverse order of removal, and note these items.
If you're installing a new compressor, drain all the refrigerant oil from the removed compressor, and measure its volume, Subtract the volume of drained oil from 120cc(4.20 oz.) the result is the amount of oil you should drain from the new compressor (through the suction fitting).
Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage.
To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately.
Adjust the drive belt.
Charge the system and test its performance.
Check the plated parts of the disc & hub assembly (A) for color changes, peeling or other damage. If there is damage, replace the clutch set.
Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag.
Measure the clearance between the pulley (B) and the disc & hub assembly (A) all the way around. If the clearance is not within specified limits, remove the disc & hub assembly and add or remove shim (gap washer) as needed to increase or decrease clearance.
Clearance: 0.45 ± 0.1mm (0.018 ± 0.004 in.)
The shims (gap washers) are available in seven thicknesses: 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm and 1.3mm.
Check operation of the magnetic clutch.
Connect the compressor side terminals to the battery (+) terminal and the ground battery (-) terminal to the compressor body.Check the magnetic clutch operating noise to determine the condition.
Compressor type: Fixed type compressor, External control valve, Internal control valve.
In cases of fixed type and internal control valve, it is possible to inspect compressor's operation with clutch noise.
When it comes to External control valve, however, it cannot be checked in this way bacause it doesn't have a clutch.
So, ECV should be inspected with GDS as below.
Connect GDS to the vehicle and select 'Aircon Compressor Test(ECV type)'
[ECV1]
Make the vehicle ready as the GDS instruction on the monitor. (Turn off A/C 'switch' only)
[ECV2]
[ECV3]
Check if other DTC codes are found before inspect ECV compressor. If so, solve that problems first. If not, press 'OK' button to continue.
Do not continue inspection if these DTC codes are found: B1241, B1242, B1672, B1685, B1686, B1687
[ECV4]
Start inspection
[ECV5]
[ECV6]
Check if condenser fan is operating when condition is changed to 'ECV running'
Relife valve will be operated if a condenser fan doesn't work because of overpressure in the compressor. It helps the airconditiong system to relieve by releasing refrigerant and oil. (Closed if relieved)
※ Refill refrigerant and oil after operation of Relife valve
※ Noise occurred when Relife vlave is in operation
Check the result of inspection.
[ECV7]
[ECV8]
If the result shows "Check" , click "Check" and follow the instruction.
Inspect ECV again from the first step.
Remove the center bolt (A) while holding the disc & hub assembly with a commercially available disc & hub assembly bolt remover; Special tool number 09977-29000.
Torque: 10~15N.m (1.02~1.53kgf.m, 7.37~11lbf.ft)
Remove the disc & hub assembly (A) and shim (gap washer) (B), taking care not to lose the shims. If the clutch needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the disc & hub assembly, and recheck its clearance.
If you removal the field coil, remove retainer ring (A) with retainer ring pliers.
Be careful not to damage the pulley (B) and compressor during removal/installation.
Once retainer ring (A) is removed, replace it with a new one.
Remove the screw (A) from the field coil ground terminal. Remove the retainer ring (B) and then remove the field coil (C) from the shaft with a puller. Be careful not to damage the coil and compressor.
Reassemble the compressor clutch in the reverse order of disassembly, and note these items :
Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
Install new retainer rings, and make sure they are fully seated in the groove.
Make sure that the pulley turns smoothly after its reassembled.
