Compressor

ON-VEHICLE INSPECTION

1. INSTALL MANIFOLD GAUGE SET

(a) Close the HI and LO hand valves.

(b) Connect the high pressure hose to the discharge service valve of the compressor.

(c) Connect the low pressure hose to the suction service valve of the compressor.

2. RUN ENGINE AT FAST IDLE

3. CHECK COMPRESSOR FOR FOLLOWING:

(a) High pressure gauge reading is not low and low pressure gauge reading is not higher than normal.

(b) Metallic sound

(c) Leakage from the shaft seal

If defects are found, repair the compressor.

4. CHECK MAGNETIC CLUTCH

(a) Inspect the pressure plate and the rotor for signs of oil.

(b) Check the clutch bearings for noise and grease leakage.

(c) Using an ohmmeter, measure the resistance of the stator coil between the clutch lead wire and ground.

If the resistance is not within tolerance, replace the coil.

Standard resistance: 3.7 ± 0.2 fi at 20°C (68°F)

Supra Ground Lead

: Specified torque

REMOVAL OF COMPRESSOR

1. RUN ENGINE AT IDLE WITH AIR CONDITIONING ON FOR 10 MINUTES

2. DISCONNECT NEGATIVE CABLE FROM BATTERY

3. DISCONNECT CLUTCH LEAD WIRE FROM WIRING HARNESS

4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-12)

5. DISCONNECT TWO FLEXIBLE HOSES FROM COMPRESSOR SERVICE VALVES

Cap the open fitting immediately to keep moisture out of the system.

6. REMOVE COMPRESSOR

(a) Loosen the drive belt.

(b) Remove the compressor mounting bolts and the compressor.

Sienna Compressor Clutch Removal

Compressor

Rotor

Fressure Plate y kg-cm (ft »b, N m)| : Specified torque

Stator

Rotor Bearing

DISASSEMBLY OF MAGNETIC CLUTCH

1. REMOVE PRESSURE PLATE

(a) Using SST and a socket, remove the shaft nut SST 07110 77011

(b) Using SST and a socket, remove the pressure plate. SST 07112 71010

(c) Remove the shims from the shaft.

REMOVE ROTOR

(a) Using SST, remove the snap ring. SST 07114 84020

(b) Using a plastic hammer, tap the rotor off the shaft.

CAUTION: Be careful not to damage the pulley when tapping on the rotor.

3. REMOVE STATOR

(a) Disconnect the stator lead wires from the compressor housing.

(b) Using SST, remove the snap ring. Remove the stator. SST 07114 84020

4. REMOVE ROTOR BEARINGS

NOTE: Press the bearings out only if they are to be replaced.

(a) Remove the bearing snap ring from the rotor.

(b) Using SST, press out the two bearings. SST 07110 77011

5. INSPECT PRESSURE PLATE AND ROTOR

(a) Inspect the pressure plate and rotor surfaces for wear and scoring. Replace if necessary.

(b) Check the rotor bearings for wear and leakage of grease. Replace if necessary.

Suction Service Valve

Cylinder Block

Piston

Thrust Bearing

Thrust Bearing

Cylinder Block

Rear Housing

♦Gasket Discharge Reed Valve

Valve Plate

Suction Reed Valve

Valve Plate Discharge Reed Valve

Front Housing

| kg-cm (ft'lb, N m)[ : Specified torque ♦ Non-reusable part_

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DISASSEMBLY OF COMPRESSOR

1. REMOVE FELT

3456 Cylinder Plate Discharge Pusher

2. REMOVE CIRCLIP

Using SST, remove the circlip. SST 07114 84020

3. REMOVE KEY

Using a hammer and punch, drive the key from the shaft.

*

4. APPLY COMPRESSOR OIL TO INNER BORE

Apply compressor oil to the inner bore of the compressor.

Inner Shaft Seal For 1992 Celica

5. REMOVE SHAFT PLATE

(a) Insert SST against the shaft. Then push the holder ring downward.

SST 07112 15010

(b) Pull up the bar of the remover, and remove the shaft plate.

k^SST

Inner Shaft Seal For 1992 Celica

6. REMOVE SHAFT SEAL

Insert SST against the shaft, and turn it clockwise while pressing in the remover.

Then remove the shaft seal.

SST 07114 15010

Sst 07110 61050

7. REMOVE TWO SERVICE VALVES

(a) Using SST, remove the bolts holding the two service valves.

SST 07110-61050

(b) Remove the O rings from the service valves and discard them.

8. DRAIN OIL INTO CONTAINER

9. REMOVE FRONT HOUSING

(a) Using SST, remove the six through bolts. NOTE: Do not reuse the six washers. SST 07110-61050

(b) Using a hammer and punch, remove the front housing by tapping on the protrusion.

CAUTION: Be careful not to scratch the sealing surface of the front housing.

10. REMOVE FRONT VALVE PLATE

Remove the two pins from the front housing. Discard the pins.

11. REMOVE REAR HOUSING

Using a hammer and punch, remove the rear housing by tapping on the protrusion.

CAUTION: Be careful not to scratch the sealing surface of the rear housing.

12. REMOVE FRONT AND REAR O-RINGS FROM CYLINDER BLOCK

Discard the O-rings.

ASSEMBLY OF COMPRESSOR

1. INSTALL REAR VALVE PLATE ON REAR CYLINDER

(a) Install the two pins in the rear cylinder.

(b) Lubricate a new O-ring with compressor oil. Install the O-ring in the rear cylinder.

(c) Install the rear suction valve over the pins on the rear cylinder.

NOTE: The front and rear suction valves are the same.

(d) Install the rear valve plate together with the discharge valve over the pins on the rear cylinder.

NOTE: The rear valve plate is marked "R".

(e) Lubricate the gasket with compressor oil. Install the gasket on the valve plate.

2. INSTALL REAR HOUSING ON REAR CYLINDER

3. INSTALL FRONT VALVE PLATE ON FRONT CYLINDER

(a) Install the two pins in the front cylinder.

(b) Lubricate a new Oring with compressor oil. Install the O ring in the rear housing.

(c) Install the front suction valve over the pins on the front cylinder.

(d) Install the front valve plate together with the discharge valve over the pins on the front cylinder.

NOTE: The front valve plate is marked with an "F".

(e) Lubricate gasket with compressor oil. Install the gasket on the valve plate.

4. INSTALL FRONT HOUSING ON FRONT CYLINDER AND TIGHTEN SIX THROUGH BOLTS

Using SST and a torque wrench, gradually tighten the six through bolts in two or three passes.

SST 07110 61050

5. INSTALL SHAFT SEAL

(a) Fit the shaft seal to SST. SST 07114-15010

Sst 07114 15010

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Insert SST, and turn it to the left while lightly press ing in. Then pull up SST.

SST 07114-15010

(b) Press in SST. SST 07112-25010

7. INSTALL KEY IN SHAFT GROOVE

Using SST and a plastic hammer, tap the key lightly.

SST 07114-45010

Put the felt inside the bore.

8. POUR COMPRESSOR OIL INTO COMPRESSOR

Compressor oil: DENSOOIL 6, SUN ISO No.SGS, or equivalent

9. INSTALL SERVICE VALVES

(a) Lubricate new O-rings with compressor oil. Install the O-rings in the service valves.

(b) Install the service valves on the compressor. Using SST and a torque wrench, tighten the bolts.

SST 07110-61050

10. CHECK SHAFT STARTING TORQUE Torque: 30 kg-cm (26 in.lb, 2.9 N m) or less

ASSEMBLY OF MAGNETIC CLUTCH

1. INSTALL TWO BEARINGS IN ROTOR

(a) Using SST, press a shield ring and two new bearings into the rotor boss until fully seated.

SST 07110-77011

(b) Install the bearing snap ring into the rotor groove.

Sst 07110 77011

2. INSTALL STATOR

(a) Install the stator on the compressor.

(b) Using SST, install the snap ring. SST 07114-84020

(c> Connect the stator lead wires to the compressor housing.

3. INSTALL ROTOR

(a) Install the rotor on the compressor shaft.

(b) Using SST. install the snap ring. SST 07114 84020

4. INSTALL PRESSURE PLATE

(a) Adjust the clearance between the pressure plate and rotor by placing shims on the compressor shaft. Standard clearance: 0.4 - 0.7 mm (0.016 - 0.028 in.)

If the clearance is not within tolerance, add or reduce the number of shims to obtain the standard clearance.

(b) Using SST and a torque wrench, install the shaft nut. SST 07110-77011

PERFORMANCE TEST OF COMPRESSOR

1. PERFORM GAS LEAKAGE TEST

(a) Put caps on both service valves.

(b) Charge the compressor with refrigerant through the charging valve until the pressure is 3 kg/cm2 (43 psi, 294 kPa).

(c) Using a gas leak detector, check the compressor for leaks.

If leaks are found, check and replace the gasket, O ring, or shaft seal.

2. IF NECESSARY FILL COMPRESSOR WITH CLEAN COMPRESSOR OIL

Remove the service valve and drain the compressor oil. Fill with new oil.

Compressor oil: DENSOOIL 6, SUNISO No. 5GS or equivalent

3. EVACUATE COMPRESSOR AND CHARGE WITH REFRIGERANT (See page AC-12)

Make sure the caps are tight and free from moisture and contamination.

NOTE: When storing a compressor for an extended period, charge it with refrigerant or dry nitrogen gas to prevent corrosion.

Simple Aircraft Control Systems

Borroughs

Nippondenso

INSTALLATION OF COMPRESSOR

1. INSTALL COMPRESSOR WITH MOUNTING BOLTS Torque: 280 kg-cm (20 ft-lb, 27 N-m)

2. INSTALL DRIVE BELT

(a) Install the drive belt to the pulley.

(b) Adjust the belt with the adjusting bolts.

(c) Using a belt tension gauge, check the drive belt tension.

Belt tension gauge:

Nippondenso BTG-20 (95506-00020) or Borroughs No. BT-33-73F

Drive belt tension

NOTE:

• "New belt" refers to a belt which has been used less than 5 minutes on a running engine.

• "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.

3. CONNECT TWO FLEXIBLE HOSES TO COMPRESSOR SERVICE VALVES

Torque: Discharge line 225 kg-cm

4. CONNECT CLUTCH LEAD WIRE TO WIRING HARNESS

5. CONNECT NEGATIVE CABLE TO BATTERY

6. EVACUATE AND CHARGE REFRIGERATION SYSTEM (See page AC-12)

CONDENSER

ON-VEHICLE INSPECTION

1. CHECK CONDENSER FINS FOR BLOCKAGE OR DAMAGE

If the fins are clogged, wash them with a water and dry with compressed air.

CAUTION: Be careful not to damage the fins.

If the fins are bent, straighten them with screwdriver or pliers.

2. CHECK CONDENSER FITTINGS FOR LEAKAGE

Repair as necessary.

REMOVAL OF CONDENSER

1. DISCHARGE REFRIGERATION SYSTEM (Seepage AC-12)

2. REMOVE FRONT GRILLE AND HOOD LOCK BRACE

3. DISCONNECT DISCHARGE FLEXIBLE HOSE FROM CONDENSER INLET FITTING

4. DISCONNECT LIQUID LINE TUBE FROM CONDENSER OUTLET FITTING

NOTE: Cap the open fittings immediately to keep moisture out of the system.

5. REMOVE CONDENSER

Remove the four bolts.

INSTALLATION OF CONDENSER

1. INSTALL CONDENSER

Install the four bolts making sure the rubber cushions fit on the mounting flanges correctly.

2. CONNECT LIQUID LINE TUBE AND DISCHARGE FLEXIBLE HOSE TO CONDENSER

Torque:

Liquid line tube 135 kg-cm

(10 ft-lb, 13 N m) Discharge flexible hose 225 kg-cm

3. INSTALL FRONT GRILLE AND HOOD LOCK BRACE

4. IF CONDENSER IS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR

5. EVACUATE, CHARGE AND TEST REFRIGERATION SYSTEM (See page AC-12)

Toyota Tercel Sight Glass Freon

RECEIVER

ON-VEHICLE INSPECTION

CHECK SIGHT GLASS, FUSIBLE PLUG AND FITTINGS FOR LEAKAGE

Use a gas leak tester. Repair as necessary.

REMOVAL OF RECEIVER

1. DISCHARGE REFRIGERATION SYSTEM (See page AC-12)

2. DISCONNECT TWO LIQUID LINE TUBES FROM RECEIVER

NOTE: Cap the open fittings immediately to keep moisture out of the system.

3. REMOVE RECEIVER FROM RECEIVER HOLDER

INSTALLATION OF RECEIVER

1. INSTALL RECEIVER IN RECEIVER HOLDER

NOTE: Do not remove blind plugs until ready for connection.

2. CONNECT TWO LIQUID LINE TUBES TO RECEIVER Torque: 135 kg-cm (10 ft-lb. 13 N-m)

3. IF RECEIVER IS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR

4. EVACUATE, CHARGE AND TEST REFRIGERATION SYSTEM (See page AC-12)

COOLING UNIT

ON-VEHICLE INSPECTION OF EXPANSION VALVE

1. CONNECT MANIFOLD GAUGE TO COMPRESSOR

2. CHECK EXPANSION VALVE OPERATION

(a) Run the engine at fast idle with the air conditioning on.

(b) Check that reading on the low pressure is between 0.5 - 5.0 kg/cm2 (7 - 71 psi, 49 - 490 kPa).

If the reading is too low, check and replace the expansion valve and/or receiver.

If the reading is too high, tighten the remote valve holders and/or replace the expansion valve.

Toyota Supra Compressor

ECTOR

REMOVAL OF COOLING UNIT

1. DISCONNECT NEGATIVE CABLE FROM BATTERY

2. DISCHARGE REFRIGERATION SYSTEM (See page AC-12)

3. DISCONNECT SUCTION FLEXIBLE HOSE FROM COOLING UNIT OUTLET FITTING

4. DISCONNECT LIQUID LINE TUBE FROM COOLING UNIT INLET FITTING

NOTE: Cap the open fittings immediately to keep moisture out of the system.

5. REMOVE GROMMETS FROM INLET AND OUTLET FITTINGS

6. REMOVE FOLLOWING COMPONENTS:

(a) Glove box with undercover

(b) Side air duct

7. DISCONNECT CONNECTORS

8. REMOVE COOLING UNIT

Remove the three nuts and four bolts.

9. REMOVE A/C AMPLIFIER

10. REMOVE A/C WIRE HARNESS FROM COOLING UNIT

DISASSEMBLY OF COOLING UNIT

1. REMOVE LOWER CASE

Using a screwdriver, remove the four clamps, and four screws.

2. REMOVE UPPER CASE FROM EVAPORATOR

Remove the two screws.

Evaporator E11

Resistor

Liquid Line Tube

Pressure Switch

Expansion Valve

Resistor

3. REMOVE COMPONENTS FROM EVAPORATOR

(a) Remove the heat insulator and the clamp from the outlet tube.

(b) Disconnect the liquid line tube from inlet fitting of the expansion valve.

(c) Disconnect the expansion valve from the inlet fitting of the evaporator.

(d) Remove the pressure switch, if required.

Evaporator

INSPECTION OF EVAPORATOR

1. CHECK EVAPORATOR FINS FOR BLOCKAGE

If the fins are clogged, clean them with compressed air. CAUTION: Never use water to clean the evaporator.

2. CHECK FITTINGS FOR CRACKS OR SCRATCHES

Repair as necessary.

ASSEMBLY OF COOLING UNIT

1. INSTALL COMPONENTS ON EVAPORATOR

(a) Connect the expansion valve to the inlet fitting of the evaporator. Torque the nut.

NOTE: Be sure that the O-ring is positioned on the tube fitting.

(b) Connect the liquid line tube to the inlet fitting of the expansion valve. Torque the nut.

(c) Install the pressure switch, if removed. Torque: 135 kg-cm (10 ft-lb, 13 N m)

(d) Install the clamp and heat insulator to the outlet tube.

2. INSTALL UPPER AND LOWER CASES ON EVAPORATOR

1997 Toyota Tacoma Evaporator Tube

¡FANSIO.WiALVE rque:. 235 kg-cm

INSTALL THERMISTOR

INSTALLATION OF COOLING UNIT

1. INSTALL A/C WIRE HARNESS TO COOLING UNIT

2. INSTALL COOLING UNIT

Install the cooling unit with the three nuts and four bolts.

CAUTION: Be careful not to pinch the wiring harness while installing the cooling unit.

3. INSTALL FOLLOWING COMPONENTS:

(a) Side air duct

(b) Glove box with undercover

4. INSTALL GROMMETS ON INLET AND OUTLET FITTINGS

5. CONNECT LIQUID LINE TUBE TO COOLING UNIT INLET FITTING

CONNECT SUCTION FLEXIBLE HOSE TO COOLING UNIT OUTLET FITTING

IF EVAPORATOR IS REPLACED, ADD COMPRESSOR

OIL TO COMPRESSOR

CONNECT NEGATIVE CABLE TO BATTERY

EVACUATE. CHARGE AND TEST REFRIGERATION SYSTEM (Seepage AC-12)

REFRIGERANT LINES

ON-VEHICLE INSPECTION

1. INSPECT HOSES AND TUBES FOR LEAKAGE

Use a gas leak tester. Replace, if necessary.

2. CHECK THAT HOSE AND TUBE CLAMPS ARE NOT LOOSE

Tighten or replace, as necessary.

REPLACEMENT OF REFRIGERANT LINES

1. DISCHARGE REFRIGERATION SYSTEM {See page AC-12)

2. REPLACE FAULTY TUBE OR HOSE

NOTE: Cap the open fittings immediately to keep moisture out of the system.

Tightening torques for the O-ring fittings.

Fitting size

Torque

0.31 in. tube for liquid line 0.50 in. tube for discharge line 0.61 in. tube for suction line

135 kg-cm (10 ft-lb, 13Nm| 225 kg-cm (16 ft-lb, 22 N m) 325 kg-cm (24 ft-lb, 32 N-m)

3. EVACUATE. CHARGE AND TEST REFRIGERATION SYSTEM (See page AC-12)

Charging Hose

To Refrigeration System

To Manifold ?

Gauge To Compressor

To Manifold ?

Gauge To Compressor aoo>w aoo>w

EXPANSION VALVE

ON-VEHICLE INSPECTION

1. CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE

2. INSTALL MANIFOLD GAUGE SET

(a) Close the high pressure and low pressure valves.

(b) Connect the high pressure hose to the discharge service valve of the compressor.

(c) Connect the low pressure hose to the suction service valve of the compressor.

3. RUN ENGINE

Run the engine at 2,000 rpm for at least 5 minutes. Then check that the high pressure reading is 13 - 15 kg/cm2 (185 - 213 psi, 1,275 - 1,471 kPa).

4. CHECK EXPANSION VALVE

If the expansion valve is faulty, the low pressure reading will drop to 0 kg/cm2. (0 psi, 0 kPa), otherwise it is OK.

NOTE: When the low pressure drops to 0 kg/cm2 (0 psi, 0 kPa), feel the receiver's IN and OUT sides for no temperature difference.

Vacum Control Motor 1kz

VACUUM SWITCHING VALVE (VSV)

(See page AC-22) INSPECTION OF VSV

1. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY

BLOWING AIR INTO PIPES

(a) Connect the VSV terminals to the battery terminals as illustrated.

(b) Blow into pipe "F" and check that air comes out of pipe c .

(c) Disconnect the battery.

(d) Blow into pipe "F" and check that air comes out of the filter "G".

If a problem is found, repair or replace the VSV.

1990 Camry Fuel Pressure Vsv

2. CHECK FOR SHORT CIRCUIT

Using an ohmmeter, check that there is no continuity between each terminal and the VSV body.

If there is continuity, replace the VSV.

Vsv Body 1990 4runner

3. CHECK FOR OPEN CIRCUIT

Using an ohmmeter, measure the resistance between the two terminals.

If resistance is not within specification, replace the VSV.

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    How to test a faulty vsv valve 1997 camry?
    9 years ago

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