Hyundai Sonata: Compressor Repair procedures - Air Conditioning System - Heating, Ventilation and Air ConditioningHyundai Sonata: Compressor Repair procedures

Removal
   
Precautions for using the plastic pulley
Take care not to give physical impact to the plastic pulley.
If exposed to the impact of dropping and collision, the pulley should not be used although not damaged.
Be careful not to place the pulley to downwards of the floor or table.

Be careful not to apply the external force and impact on pulley while moving or using.

Be careful not to apply force to the pulley.

1.
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.
2.
Disconnect the negative (-) battery terminal.
3.
Recover the refrigerant with a recovery/charging station.
4.
Remove the engine room cover.
(Refer to Engine Mechanical System - " Engine Room Cover")
5.
Loosen the drive belt.
(Refer to Engine Mechanical System - " Drive Belt")
6.
Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor.

Tightening torque :
7.8 ~ 11.8 N.m ( 0.9 ~ 1.2 kgf.m, 5.8 ~ 8.7 Ib-ft)

   
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

7.
Disconnect the compressor switch connector (A).

8.
Remove the compressor (A) by loosening the mounting bolts.

Tightening torque :
20.0 ~ 32.95 N.m (2.04 ~ 3.36 kgf.m, 14.75 ~ 24.30 Ib-ft)

[Gamma Engine]

[Theta Engine]

Inspection
1.
Check the plated parts of the limiter & hub assembly (A) for limiter breaking and other damage. If there is damage, replace the assembly.
2.
Check the pulley (B) bearing play and drag by rotating the pulley by hand and pulley breaking. Replace the assembly with a new one if it is noisy or has excessive play/drag.

External Control Valve Compressor Inspection (GDS)
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.
1.
Connect GDS to the vehicle and select 'Aircon Compressor Test(ECV type)'
[ECV1]

2.
Make the vehicle ready as the GDS instruction on the monitor. (Turn off A/C 'switch' only)
[ECV2]

[ECV3]

3.
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]

4.
Start inspection
[ECV5]

[ECV6]

   
Check if condenser fan is operating when condition is changed to 'ECV running'
   
Relief valve will be operated if a condenser fan doesn't work because of overpressure in the compressor. It allows the A/C system to relieve overpressure by releasing refrigerant and oil. (Closed if relieved)
? Refill refrigerant and oil after operation of relief valve
? Noise can be observed as the relief valve is in operation
5.
Check the result of inspection and click 'Check Detail' if it's 'Check'. Follow the instruction and inspect ECV again from the first step.
[ECV7]

[ECV8]

Installation
1.
Make sure the compressor (A) mounting bolt with the correct length is screwed in. Tighten the mounting bolts with the specified tightening order.

Tightening torque :
20.0 ~ 32.95 N.m(2.04 ~ 3.36 kgf.m, 14.75 ~ 24.30 Ib-ft)

[Gamma Engine]

[Theta Engine]

2.
Install in the reverse order of removal.
   
If you install a new compressor, drain all the refrigerant oil from the removed compressor and measure its volume. Subtract the volume of drained oil from the original capacity. The result is the amount of oilcompressor 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.
After assembling the compressor, check the problems (cracks, leak,etc.) with the naked eye.
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