Tucson 2006-2008

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. 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.
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  5. Disconnect the negative cable from the battery.
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  7. Recover the refrigerant with a recovery/charging station.
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  9. Remove the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
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  11. Remove the nuts, then disconnect the suction line (A) and discharge (B) line from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

    Click image to see an enlarged view

    Fig. Air compressor lines location

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  13. Disconnect the compressor clutch connector (A), then remove the mounting bolts and the compressor (B).

    Click image to see an enlarged view

    Fig. Disconnect the compressor clutch connector (A), then remove the mounting bolts and the compressor (B)

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  15. Using a hexagon wrench (6mm) remove the bolts, the manifold assembly (A), and the gasket (B) from the compressor.

    Click image to see an enlarged view

    Fig. Remove the bolts, the manifold assembly (A), and the gasket (B) from the compressor

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To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Note these items:
    WARNING
    Do not spill the refrigerant oil on the vehicle, it may damage the paint. If the refrigerant oil contacts the paint, wash it off immediately.



    If you're installing a new compressor, drain all the refrigerant oil from the removed compressor, and measure its volume. Subtract the volume of drained oil from the required amount of oil (200ml). The result is the amount of 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.
     



    Adjust the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
     
    Evacuate, charge the system, and test its performance.
     

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