Guidelines for compressor installation in the AC system

Identifying & solving Problem Cause How to identify Why the problem occurs Solution Preventive action

typical failures of the compressors • To avoid damage to the compressor shaft

• Leakage in the compressor shaft: seal of the shaft is sealing, the system should be used on a regular
dried out because the compressor has not been used for basis (min 30 minutes a week)
Compressor a longer period of time thus the seal was not lubricated
leakage or • Apply parts that are corrosion protected (e.g.
Use an UV dye agent or another leakage detecting • Surface damage of condenser because of stones/ • Replace the damaged parts, as well as: receiver- Nissens condensers)
leakage in equipment to identify leakages insects, corrosion, or damage for the system hoses due dryer/cartridge or accumulator
other system to frictions / physical impact from other parts • Always replace o-rings when installing
components a new part in the system

2
Determine • The system connections are not sealed because of worn

1
out o-rings • Check regularly for corrosion on the AC system
metal parts (hoses and tubes especially)
the cause of While the AC system is switched on and set to produce a
Does
the breakdown not The compressor
low temperature, the compressor pulley spins but the hub
does not turn
• The voltage in the system is too low thus the coil/clutch
does not get enough electrical power to engage
• Check the electrical system to determine the
cause of the low voltage, thoroughly check the
Examine create compressor connections and wiring
clutch does not • Electrical plugs of the compressor are not connected
Use Visual Diagnostic high- and enough engage properly • When installing a new compressor, make sure
Tool when checking • Make sure that the car computer software
low-side or any is up to date
that all wirings are connected properly and they
for contamination When switching the AC system ON/OFF, • The wiring is not properly insulated (short cut) are insulated
In case of contamination, for contamination pressure (compressors with a 'click' must be heard from the compressor clutch • Replace the compressor if the problem is caused
• The shims/spacers of the compressor create
repeat step 3 magnetic clutch) a distance between the hub and the pulley
by the too long distance between pulley and hub
that is bigger than 0.8 mm

8 3
The AC system is on but produces cold air only
• Replace the following parts: O-rings, receiver
periodically
dryer, dryer cartridge, accumulator tank,
• Perform a proper vacuum
compressor, expansion valve, orifice tube
• Insufficient vacuum during system when servicing the AC system
Moisture in the repair (installation of a new component) or service or when installing a new part
• It is highly recommended to replace
system Expansion valve freezes the condenser
Ensure the correct • Leakage in the system • Make sure that the refrigerant charged in the
oil and quantity In case of • The system must be flushed, otherwise all hoses,
system is 100% clean and free of moisture
in the compressor contamination tubes and evaporator must be replaced

Pressure test the flush the system The compressor oil is black or contaminated • Bad condition of the condenser causes overheating of
AC system when
installing new with R134a or a Clutch has a brown or rusty color the refrigerant and the oil
• Replace the following parts: O-rings, receiver
components flushing detergent Physical damages to the condenser (mainly, fins of the • Reduced or insufficient flow in the AC system caused by dryer, dryer cartridge, accumulator tank,
• Carefully follow Nissens' compressor installation
guide.
Pull vacuum and designed for Too high operation
condenser are broken or missing) particles, e.g. clogged drier/condenser/expansion valve compressor, expansion valve, orifice tube
or orifice tube, the system was not flushed properly
recharge the
system with the
flushing temperature of • It is highly recommended to replace
• Always use the right amount and type of oil
dedicated to a specified vehicle
recommended Does not create the compressor • Improper amount of oil or refrigerant in the system the condenser

4
refrigerant causing overheating
enough or any • The amount of UV dye used must never exceed

7
Check the belt
tensioner if broken
Check the hoses
for visual defects
Replace the parts
if needed
Broken hub on externally controlled compressors • The system must be flushed, otherwise all hoses,
pressure 5% of the total volume of the oil
• A dysfunction fan, interior blower or clogged air cabin tubes and evaporator must be replaced
filter causes the pressure increase in the system, thus
the temperature to rise
or
Check the condenser for The shaft is stuck or broken • Replace the following parts: O-rings, receiver
visual defects, e.g. missing Excessive
dryer, dryer cartridge, accumulator tank,
compressor, expansion valve, orifice tube
or corroded fins. Replace if noise from the • Improper operation of the expansion valve • Perform the right vacuum procedure when
necessary. compressor Fluid Hammer • It is highly recommended to replace assembling the system
Noisy, hammering sound from the compressor • Insufficient vacuum of the system the condenser and replacing the expansion valve
Always replace
For externally
the receiver drier • The system must be flushed, otherwise all hoses,
controlled tubes and evaporator must be replaced
compressors,

6
Bearing of the • Low refrigerant level causes too high temperature • Carefully follow Nissens’ compressor installation

5
check the the valve A rattling noise from the compressor • Replace the compressor
pulley is damaged thus dries out bearing guidelines
if broken by means
of Compressor
Load Tester Excessive
noise from the
compressor
• Fill the AC system with the right amount of
Low refrigerant refrigerant
Filling station indicates that there is not enough
or level in the refrigerant
• Leakage in the system • Follow the service guidelines for the AC system.
• Determine leakage in the system,
system
replace leaking parts
Whistling
noise from
Remember during installation the dashboard

• Impurities in the system, the system was not flushed • Always replace the expansion valve when
Expansion valve
during repair/service installing a new compressor
does not operate The valve is clogged by impurities in the system • Replace the expansion valve, flush the system
• Nissens’ installation and warranty Whistling properly • The expansion valve is defective • Flush the system
guide is always included in the box noise from
Too low pressure on the system suction side
of all Nissens’ compressors Evaporator Compressor the dashboard
or available online at Clogged AC • Impurities in the system, the system was not flushed
• Replace all parts in the system, flush the system • Flush the system
system Too high pressure on discharge side during repair/service
www.nissens.com/guides
Expansion valve
or by scanning the QR code.

• Safety first - wear protection Compressor placement in the system

gloves and glasses Condenser

The compressor is the heart of the air conditioning system. The refrigerant is compressed by the compressor and transported through the system to create high and
Receiver-dryer
low pressure. The compressor is crucial for the efficiency of the AC system.
N I S S EN S ’
THE RADIATORS
INTERCOOLERS
CONDENSERS
WIDEST COMPRESSORS
BLOWERS

PRODUCT
DRYERS
EVAPORATORS
During an AC cycle, the compressor enables the coolant to change its form from gas to liquid and flow through the components of the system as well as through Concept OIL COOLERS
AC-fan
high and low pressure sides. RANGE HEATERS
FANS