Removal and installation of the compressor
Removing the compressor.
1 - compressor, 2 - compressor mounting bracket (G4JP and G4JS engines), 3 - bolt.
1. Remove the battery and battery tray.
2. Remove the cooling fan diffuser.
3. Pump out the refrigerant from the system.
4. Loosen the compressor drive belt tensioner pulley.
5. Disconnect the high pressure hose.
6. Remove the compressor.
7. Installation is made in an order, the return to removal.
8. When installing the parts, pay attention to the installation operation of the compressor.
If a new compressor is being installed, pre-adjust the amount of oil filled into it as indicated below, and then install the compressor (those. maintain oil balance in the air conditioning system).
- A) Measure the amount of oil [X ml] that was in the removed compressor.
- b) Drain the amount of oil [Y ml] calculated from the formula below from the new compressor, and then install the new compressor in place.
- Oil volume in the new compressor: 150 ml - X ml - Y ml
Note: [Y ml] refers to the amount of oil left in the pipes, condenser, evaporator, hoses, etc.
Amount of oil added when replacing components:
- Vaporizer: 30ml
- Capacitor: 40ml
- Receiver drier: 20 ml
- Compressor: 50 ml
- Tube or hose: 10 ml
Attention:
- Compressor oil must be free of moisture, contaminants, particles, metals, etc.
- Do not mix compressor oils of different grades.
- Compressor oil is very hygroscopic, so do not leave the oil container open for a long time (those. longer than
- it is necessary for refueling). Close container immediately after use.
Removing the Pressure Plate and Clutch Rotor
1. Loosen the pressure plate mounting bolt using a wrench and special tool.
2. Remove the pressure plate and shim from the compressor shaft. If the pressure plate cannot be removed by hand, tighten the bolt (M8) into the center hole of the plate so that the plate comes off and can be removed.
3. Remove the clutch rotor retaining ring.
4. Remove the clutch rotor assembly with bearing from the compressor.
Installing the Pressure Plate and Clutch Rotor
1. Clean the bearing seat of the clutch rotor on the compressor shaft, remove any traces of dirt and rust.
2. Install the clutch rotor assembly with bearing on the compressor shaft.
3. Install the clutch rotor retaining ring with the chamfered side facing out.
4. Place a shim of the appropriate thickness on the splines of the pressure plate on the compressor side and slide the plate smoothly onto the compressor shaft.
5. Install a new pressure plate bolt onto the end of the compressor shaft. Tighten the bolt to the specified torque.
- Tightening torque: 10-15 Nm
Attention: do not use pneumatic tools (impact wrench) when performing this operation.
Removal and installation of the winding of the electromagnetic clutch
Removing the electromagnetic clutch of the compressor.
1 - bolt, 2 - pressure plate, 3 - shim, 4 - retaining ring, 5 - clutch rotor assembly with bearing, 6 - clutch winding, 7 - clutch connector, 8 - gasket, 9 - compressor assembly, 10 - block of fittings, 11 - bolt.
1. Remove pressure plate and clutch rotor.
2. Install the guard on the compressor shaft.
3. Install the pulley on the compressor shaft. Align the end of the puller bolt with the alignment groove of the compressor shaft guard and position the tabs of the puller around the rear face of the coupling winding.
4. Remove the clutch winding from the compressor shaft by turning the puller bolt with a wrench.
Attention: do not use pneumatic tools (impact wrench) when performing this operation.
5. Installation is made in an order, the return to removal.
Checking the gap in the electromagnetic clutch
1. Use a feeler gauge to measure the air gap between the magnetic clutch pressure plate and the contact surface of the clutch rotor.
- Rated clearance: 0.35-0.65mm
2. Measure the gap at three points around the circumference of the compressor clutch rotor.
3. If the measured clearance is out of specification range, adjust the clearance as necessary by installing a shim of appropriate thickness.