Hyundai Genesis: Air Conditioning System / Compressor Repair procedures

Removal
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.
Remove the engine room cover.
(Refer to Engine Mechanical System - "Engine room cover")
4.
Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Air cleaner")
5.
Recover the refrigerant with a recovery/charging station.
6.
Remove the engine room under cover (A).

7.
Loosen the drive belt.
(Refer to Engine Mechanical System - "Timing System")
8.
Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor.

Tightening torque :
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

   
Plug or cap the lines immediately after disconnecting them to avoid the intrusion of moisture and dust.
9.
Disconnect the compressor switch connector (A).

10.
Remove the compressor (A) by loosening the mounting bolts.
[Lambda Engine]

[Tau Engine]

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

Tightening torque :
20.00~32.95 N.m (2.04~3.36 kgf.m, 14.75~24.30 lb-ft)

[Lambda Engine]

[Tau 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 the 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 types of refrigerant oil.
Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
Inspection
1.
Check the plated parts of the hub assembly (A) for discoloration, peeling or other damage. If there is damage, replace the assembly.
2.
Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the pulley 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 because 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 according to the GDS instruction on the monitor. (Turn off A/C 'switch' only)
[ECV2]

[ECV3]

3.
Check if other DTC codes are found before inspecting 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'
   
Relife valve will be operated if a condenser fan doesn't work because of overpressure in the compressor. It helps the air conditioning system to be stabilized. by releasing refrigerant and oil. (To be closed if stabilized.)
? Refill refrigerant and oil after operation of Relife valve.
? Noise occurs when Relife 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]

Disassembly
1.
Remove the engine room under cover.
2.
Loosen the drive belt.
(Refer to Engine Mechanical System - "Timing System")
3.
Remove the center bolt (A) while holding the pulley with a disc & hub assembly.

Tightening torque :
10 ~ 15 N.m (1.0 ~ 1.5 kgf.m, 7.4 ~ 11.0 lb-ft)

4.
Loosen the mounting bolts and then remove the disc & hub assembly (A).

5.
Remove the pulley (B) after removing the snap ring (A) with snap ring pliers.

   
Be careful not to damage the pulley and compressor during disassembly/reassembly.
Once the snap ring is removed, replace it with a new one.
6.
Reassemble in the reverse order of disassembly.
   
Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
Install a new snap ring, and make sure they are fully seated in the groove.
Make sure that the pulley turns smoothly after reassembly.
Compressor Components and Components Location
Components [Lambda Engine] 1. Center Bolt2. Hub Bolt3. Limiter & Damper Assembly4. Snap Ring5. Pulley6. Compressor Assembly [Tau Engine] 1. Center Bolt2. Hub Bolt3. Limiter & D ...

Condenser Repair procedures
Inspection 1. Check the condenser fins for clogging and damage. If they are clogged, clean them with water, and blow them with compressed air. If they are bent, gently bend them using a screwd ...

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