AC Compressor Installation Instructions
Contents
1. Mitsubishi Mitsubishi FX MSC 59007 409503 Mitsubishi Nippondenso 10P 10PA 59007 409503 New Holland Sanden SD 59007 409503 Nissan Diesel Kiki Zexel DKV DCV 59003 409501 Nissan Calsonic Rotary 59007 409503 Nissan Diesel Kiki Nihon DKS Rotary 59007 409503 Nissan Diesel Kiki Zexel DKV Rotary 59003 409501 Opel Delphi Harrison V5 59003 409501 Opel Nippondenso 6CA 59007 409503 Opel Sanden 7SB 59007 409503 Peterbilt Sanden SD 59002 409502 Peugeot Sanden SD 59002 409502 Peugeot Sanden SDV 59007 409503 Porsche Nippondenso 10P 59007 409503 Peugeot Sanden SD7 59002 409502 Renault Sanden SDV 59007 409503 Renault Sanden SD7 59002 409502 Renault Sanden TRS 59007 409503 Renault Zexel DKS 15CH 59007 409503 Rolls Royce Sanden SDV 59007 409503 Rover Sanden SD7 59002 409502 Rover Sanden SDV 59007 409503 Rover Nippondenso 10P 59007 409503 Saab Seiko Seiki SS 59007 409503 Saab Sanden 59009 409500 Saab Nippondenso 7SB 59007 409503 Seat Sanden SDV 59007 409503 Skoda Sanden SD7 59002 409502 Subaru Zexel Rotary 59003 409501 Subaru Diesel Kiki 15CH 59007 409503 Suzuki Sanden SD 59002 409502 Suzuki Nippondenso 10P 59007 409503 Toyota Nippondenso 10P 10PA 59007 409503 Toyota Nippondenso TV 59002 409502 Vauxhaul GM Delphi Harrison V5 59003 409501 Volkswagen Sanden SD SD7 59002 409502 Volkswagen Sanden SDV 59007 409503 Volkswagen Sanden 7SB 59007 409503 Volkswagen Zexel DCW 59007 409503 Volvo Seiko Seiki SS 59007 409503 Volvo Sanden SD SD7 59002. Ibs HS 20 15 0 22 6 ft Ibs 14 21 ft Ibs 12 5 ft Ibs N A N A 12 0 19 2 ft Ibs 13 1 17 3 ft Ibs 7 5 11 3 ft Ibs 0157 0236 014 026 014 026 014 026 7 5 11 3 ft Ibs Shim 7 5 11 3 ft Ibs Shim 7 5 11 3 ft Ibs Shim 7 5 11 3 ft Ibs Shim KEIHIN Refer to OEM Specification 012 024 33 ft Ibs Shim MATSUSHITA 36 ft Ibs 16 ft Ibs 015 030 MITSUBISHI 36 ft Ibs NIHON CALSONIC 36 ft Ibs 16 ft Ibs 16 ft Ibs 015 030 015 030 Shim NIPPONDENSO 10P 36 ft Ibs 16 ft Ibs 016 030 10 ft Ibs Shim NIPPONDENSO 6E 36 ft Ibs 16 ft Ibs 016 030 12 ft Ibs Shim NIPPONDENSO 6P 36 ft Ibs 16 ft Ibs 020 035 12 ft Ibs Shim PANASONIC NA1301 19 ft Ibs 10 14 ft Ibs 016 030 id Shim 40 ft Ibs 24 ft Ibs 30 ft Ibs Diesel 25 ft Ibs 020 040 N A Press Fit SD 508 510 709 SEIKO SEIKI 16 20 ft Ibs Refer to OEM Specification 014 026 10 ft Ibs Shim 30 ft Ibs 17 ft Ibs 016 031 10 ft Ibs Shim 10 ft Ibs Shim SELTEC TR 70 TR105 TRFO90 TRSO90 TV12 TV14 V5 YORK 206 YORK 209 210 40 ft Ibs Check with the OEM for each vehicle for these specifications Not available from TCD Temperature Control Division 1801 Waters Ridge Dr e Lewisville TX 75057 Copyright 2008 Refer to OEM Specification 015 030 01
3. moisture that has seeped into the A C system Moisture in an A C system can form corrosive contaminates that will cause rapid system failure It is very important to remove all moisture from the A C system before charging REPLACE OR INSPECT THE CONTROL DEVICES The orifice tube is a control and filter device for accumulator systems and should always be replaced to ensure proper refrigerant and oil flow through the system The thermal expansion valve is the control device for systems using a receiver drier It should be examined and replaced if found to be contaminated A Clean A C System is Imperative When a compressor fails tiny internal particles mix with oil and spread throughout the entire system This contaminated oil as well as moisture and other corrosives must be removed to avoid premature failure of the replacement compressor Clean the entire system thoroughly with an effective cleaning agent and or replace contaminated parts Air alone does not remove contaminants Two methods used today are effective in removing oil and contaminants 1 liquid cleaning with an effective cleaning agent Flushing with Dura Flush II or similar non oil based flush designed specifically for automotive A C use is a proven method to clean A C system components when used with a flush cylinder and pressurized air Closed loop flushing with a power flush machine and the machine manufacturer s approved solvent is an effective method to clean A C sy
4. 09503 Jeep Eagle Sanden SD 59002 409502 Jeep Eagle Sanden TR 59007 409503 Jeep Eagle Nippondenso 10P 10PA 59007 409503 Citroen Sanden SD7 59002 409502 Citroen Sanden SDV 59007 409503 Citroen Harrison V5 59003 409501 Ferrari Sanden SDV 59007 409503 Fiat Sanden SD7 59002 409502 Fiat Nippondenso SC8 59007 409503 Ford Ford FS10 FX15 59007 409503 Ford Nippondenso 10P 10PA 59007 409503 Ford Sanden SD 59002 409502 Ford Panasonic Rotary 59007 409503 Ford Ford FS6 59007 409503 Ford Harrison A6 59003 409501 Ford Sanden TR TRS 59007 409503 Ford Ford FS 18 FS 20 59007 409503 Ford Ford Scroll 59007 409503 G M Delphi Harrison V5 Retro 59003 409501 G M Delphi Harrison V5 R134a 59003 409501 G M Four Seasons 88 series HR6 HD6 HT6 59007 409503 G M Delphi Harrison HR6 HD6 HT6 59003 409501 G M Delphi Harrison R4 59003 409501 G M Nippondenso 10PA 59007 409503 G M Sanden SD7 59002 409502 G M Sanden SD5 59002 409502 Geo Nippondenso 10PO 59007 409503 G M Saturn Diesel Kiki Zexel DKV 59003 409501 G M Saturn Diesel Kiki Zexel DCV 59003 409501 G M Harrison CVC 59003 409501 Honda Sanden TR 59007 409503 Honda Sanden SD 59002 409502 Honda Nippondenso 10P 59007 409503 Honda Nippondenso HADSYS 7 Cyl 59007 409503 Hyundai Ford FX15 FS10 59007 409503 Hyundai Halla FX15 FS10 HS 15 17 18 20 59007 409503 Infinity Zexel 59003 409501 Infinity Calsonic CVW 59007 409503 Infinity Zexel 59007 409503 Isuzu Zexel 59007 409503 I
5. 2 409502
6. 2 ft Ibs Shim 12 ft Ibs Shim N A Press Fit Refer to OEM Specification 015 030 7 Shim 30 ft Ibs 2 2 2 5 40 ft Ibs 3 0 30 ft Ibs 3 3 3 5 21 ft Ibs 2 2 2 5 40 ft Ibs 3 0 30 ft Ibs 3 3 3 5 15 20 ft Ibs 2 2 2 5 15 20 ft Ibs 3 0 15 20 ft Ibs 3 3 3 5 020 035 12 ft Ibs Shim 50 ft Ibs 50 ft Ibs 20 ft Ibs 012 024 106 In Ibs DCV DKV KC 50 30 ft Ibs 17 ft Ibs 016 030 10 ft Ibs DCW DKS 30 ft Ibs 17 ft Ibs 016 030 10 ft Ibs FORD FS6 17 ft Ibs to 25 ft Ibs 17 ft Ibs to 25 ft Ibs 15 20 ft Ibs 020 035 12 ft Ibs Shim FORD FX15 FS10 15 21 ft Ibs N A 13 17 ft Ibs 013 033 12 ft Ibs Shim Ford Scrolls FS 18 FS 20 HG 500 HG850 Refer to OEM Specification HG 1000 Bolts 35 ft Ibs Nuts 2 18 ft Ibs Bolts 35 ft Ibs Nuts 2 18 ft Ibs Refer to OEM Specification N A 11 ft Ibs 014 026 10 ft Ibs Shim i Eal 014 030 014 026 Refer to OEM Specification 13 ft Ibs Shim 10 ft Ibs Shim 20 ft Ibs Non Adjustable 20 ft Ibs Non Adjustable HITACHI AXIAL Refer to OEM Specification 015 033 Shim HITACHI RADIAL 36 ft Ibs 16 ft Ibs 015 033 i Shim HR6 DA6 HR6HT 40 ft Ibs 37 ft Ibs 25 ft Ibs 015 025 Press Fit HS 15 HS 17 15 0 22 6 ft Ibs N A 12 0 19 2 ft Ibs HS 18 14 8 18 4 ft
7. 5 030 10 ft Ibs Shim 30 ft Ibs 17 ft Ibs 013 025 10 ft Ibs Shim Refer to OEM Specification Refer to OEM Specification 37 ft Ibs Refer to OEM Specification Refer to OEM Specification 25 ft Ibs 014 026 016 024 015 025 Refer to the O E Manufacturer s Specifications when installing a compressor COMPRESSOR OIL CHART The following chart is a guideline to be used only if you do not have access to the OE specs It is recommended that all of the original oil be flushed out of the system when performing major repairs This chart is for vehicles using R134a both OE and retrofitted VEHICLE COMPRESSOR COMPRESSOR Part MANUFACTURER MANUFACTURER MODEL Number All Hybrid Vehicle 59889 409610 Acura Nippondenso 10P 59007 409503 Alfa Romeo Sanden SDV 59007 409503 Alfa Romeo Nippondenso SC8 59007 409503 Audi Diesel Kiki Zexel DCW 59007 409503 Audi Nippondenso 10P 59007 409503 Audi Sanden SDV 59007 409503 BMW Seiko Seiki SS 59007 409503 BMW Nippondenso 10P 59007 409503 BMW Bosch Behr Wing 59007 409503 BMW Bosch Behr Axial 59003 409501 Chrysler Nippondenso 10PA 59007 409503 Chrysler Nippondenso 6C 6CA 59007 409503 Chrysler Sanden TR TRS 59007 409503 Chrysler Sanden SD 59002 409502 Chrysler Mitsubishi FX 59007 4
8. COMPRESSOR INSTALLATION INSTRUCTIONS Always Practice Safety First Air Bags Caution No Smoking Wear Eye Protection Work in a well ventilated area Wear Skin Protection gloves Recover refrigerant before making repairs OOcoooo Follow all Federal State and Local Regulations Proper A C performance is dependent on all systems performing properly Make certain that the engine cooling system is at peak operation and that the cooling fan fan clutch is operating properly Worn belts idlers and tensioners can cause poor cooling system performance due to belt slippage Low voltage at the A C clutch assembly can cause premature compressor failure Contaminated refrigerant continues to be one of the most significant problems facing the A C service industry today Use a refrigerant identifier to verify that the refrigerant in the system is not contaminated with a blend refrigerant or has a high concentration of air When mounting the replacement compressor to the vehicle the compressor must fit or rest with even contact at each mounting point Warped brackets must be completely straightened or replaced Leave mounting bolts loose until all bolts are in place Tighten bolts equally according to torque specs for that specific compressor Do Not Over Tighten Over Tightening Causes Leaks Replace the Filter Drier or Accumulator All Filter Driers and Accumulators contain a desiccant material This material is designed to absorb the
9. e an electronic leak detector or fluorescent dye to check for leaks A leak will cause system failure When repairs are finished ensure that the job is done right the first time by doing temperature drop testing Suggested A C tools amp equipment A C O Ring Lube Charging Cylinder Gauge Set Leak Detector Refrigerant Identifier Spanner Wrench Vacuum Pump OUOOOOUD This compressor is warranted to be free from defects in materials and workmanship at the time of its manufacture See your supplier for details of the terms and conditions of this warranty Temperature Control Division 1801 Waters Ridge Dr Lewisville TX 75057 Tech Tips can be found at www 4s com COMPRESSOR MOUNTING TORQUE AND CLUTCH AIR GAP NOTE This is a reference guide only Always refer to OEM for specific application when available Torque Compressor to Engine Torque Compressor to Bracket Torque Manifold Fitting Method of Adjustment Torque Shaft Nut 2 CY 2C90 Refer to OEM Specification 20 ft Ibs Non Adjustable 30 ft Ibs 2 2 2 5 40 ft Ibs 3 0 30 ft Ibs 3 3 3 5 30 ft Ibs 2 2 2 5 40 ft Ibs 3 0 30 ft Ibs 3 3 3 5 21 ft Ibs 2 2 2 5 40 ft Ibs 3 0 30 ft Ibs 3 3 3 5 21 ft lbs 2 2 2 5 40 ft Ibs 3 0 30 ft Ibs 3 3 3 5 Refer to OEM Specification 15 20 ft Ibs 2 2 2 5 15 20 ft Ibs 3 0 15 20 ft Ibs 3 3 3 5 15 20 ft Ibs 2 2 2 5 15 20 ft Ibs 3 0 15 20 ft Ibs 020 035 020 035 022 057 1
10. ly lube or ICE 32 DO NOT DRAIN Add the correct type and amouni of lubricant per specific system specifications Use only the recommended Refrigerant Type and Amount Only R12 or R134a can be used to maintain proper system performance The correct amount of charge is critical for system efficiency and durability because the refrigerant carries the lubricant through the system Specifications can be found in the Capacities Guide the under hood decal or an O E service manual Tip Dual A C systems require additional refrigerant and oil check vehicle specifications Compressor Rotation Always rotate the compressor shaft at least 10 revolutions after the hoses are connected and prior to starting the engine This will pump the excess liquid lubricant out of the compressor cylinders and into the system Clutch Clutch coil voltage should be within one volt of system operating voltage Anything less weakens the magnetic force of the clutch allowing slippage increased heat and failure Clutch air gap between hub and pulley is important and should be checked before installation to ensure no changes have occurred during shipping and handling Ask your suppliers for air gap specifications TIP After installation with the engine idling switch the compressor off and on 10 to 12 times This will burnish the hub and pulley face removing any machining glaze or rust inhibitors and enhance complete surface contact Verify the Repair Us
11. stem components This cleaning method is utilized by several major OE service providers 2 closed loop power cleaning using a refrigerant Note Newer condenser designs are difficult if not impossible to thoroughly clean and in many cases must be replaced Proper Evacuation The A C system must be free of moisture and air to work properly Removing the air and moisture with an A C system vacuum pump for a minimum of forty five minutes to an hour is necessary to deliver proper long lasting A C performance Lubrication The only moving component in the A C system is the compressor and adequate lubrication is critical If oil or refrigerant charges are incorrect internal damage to the compressor will occur If uncertain about the proper lubricant type or amount refer to the Capacities Guide the under hood decal or an O E service manual To ensure proper compressor lubrication install half the required system oil in the suction side This may require turning the compressor shaft as the oil is installed The remaining amount of required system oil should be installed in the accumulator or low side of the system To ensure that the front seal is lubricated and does not leak after the oil is installed the compressor must be placed or held with the front seal down for 1 to 3 minutes to allow oil to coat the seal If this seal is not lubricated before installation refrigerant may leak REMEMBER Compressors are shipped with assemb
12. suzu G M V5 59007 409503 Isuzu Diesel Kiki Zexel KC50 59003 409501 Isuzu Diesel Kiki Zexel Rotary 59007 409503 J I Case Sanden SD 59002 409502 Jaguar Sanden SD7H 59002 409502 Refer to the O E Manufacturer s Specifications when installing a compressor COMPRESSOR OIL CHART The following chart is a guideline to be used only if you do not have access to the OE specs It is recommended that all of the original oil be flushed out of the system when performing major repairs This chart is for vehicles using R134a both OE and retrofitted VEHICLE COMPRESSOR COMPRESSOR Part MANUFACTURER MANUFACTURER MODEL Number Jaguar Sanden SD 59002 409502 John Deere Nippondenso 10P 59007 409503 Lamborghini Sanden SD7 59002 409502 Lancia Sanden SD7 59002 409502 Mack Sanden SD 59002 409502 Land Rover Sanden TRS 59007 409503 Land Rover Sanden SD7 59002 409502 Lexus Nippondenso 10PA 59007 409503 Lotus Sanden SD 59007 409503 Mazda Panasonic Rotary 59007 409503 Mazda Nippondenso TV 59002 409502 Mazda Ford FS10 59007 409503 Mazda Sanden SD 59002 409502 Mazda Zexel 59007 409503 Mercedes Harrison A6 R4 59003 409501 Mercedes Nippondenso 6CA 59007 409503 Mercedes Nippondenso 10P 10PA 59007 409503 Mercedes Sanden SD6V 59007 409503 Mercedes York 59009 409500
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