COMPRESSOR(for V35A-FTS 2WD) INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

PROCEDURE


  1. ADJUST COMPRESSOR OIL


    1. When replacing the compressor assembly with pulley with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil before installation.

      Note


      • If a new compressor assembly with pulley is installed without removing the same amount of compressor oil as is remaining in the pipes, the amount of compressor oil will be excessive. This prevents heat exchange in the refrigerant cycle and will cause the air conditioning system to malfunction.

      • A certain amount of compressor oil remains in the compressor assembly with pulley during circulation and the compressor may be damaged if the amount of compressor oil is more/less than this amount. Therefore, make sure to adjust the amount of compressor oil correctly.

      • If the amount of compressor oil remaining in the removed compressor assembly with pulley is excessively low, check for compressor oil leaks.

      • Make sure to use ND-OIL 8 or equivalent compressor oil.

    2. B006EGO

      Remove the drain bolt (seal washer) from the removed compressor assembly with pulley.

    3. Drain the compressor oil from the oil port of the removed compressor assembly with pulley as shown in the illustration.

      Note

      Make sure to drain the compressor oil from the oil port.

      B006CRFC01
      *a Oil Port *b Turn Clockwise
    4. B006EGO

      Remove the drain bolt (seal washer) from the new compressor assembly with pulley.

      Tech Tips

      The drain bolt (seal washer) can be reused.

    5. Drain the following amount of compressor oil from the oil port of the new compressor assembly with pulley as shown in the illustration.

      Standard
      (The amount of oil in a new compressor assembly with pulley: 100 to 115 cc (3.38 to 3.89 fl.oz)) - (The amount of oil in the removed compressor assembly with pulley) = The amount of oil to be removed from the new compressor assembly with pulley.

      Note


      • Make sure to drain the compressor oil from the oil port.

      • Make sure to add the compressor oil from the oil port, not from the discharge or intake port.

      • If a tool is used to add compressor oil to the new compressor assembly with pulley, make sure that it is free of foreign matter.

      • If the compressor is damaged by a vehicle collision, etc., compressor oil is spilled and the compressor oil cannot be managed, replace the compressor with a supply part as follows. If the cooler condenser assembly is also replaced, do not add the specified amount of compressor oil for cooler condenser assembly replacement (40 cc (1.35 fl.oz)).

        w/o Rear Cooler
        Install it without changing the amount of compressor oil from the packaged condition.
        w/ Rear Cooler
        Before installing, remove 30 cc (1.01 fl.oz) of compressor oil from the packaged condition.
      B006CRFC01
      *a Oil Port *b Turn Clockwise

    6. Install the drain bolt (seal washer) to the new compressor assembly with pulley.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Make sure that there is no damage or foreign matter on the seal washer edge.

  2. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY


    1. B006D1N

      Using an E8 "TORX" socket wrench, install the 2 stud bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. B006AJYC02
      B006AHR Bolt
      B006EC9 Nut

      Install the compressor assembly with pulley with the 2 nuts and 2 bolts.

      Note

      Tighten the 2 nuts and 2 bolts in the order shown in the illustration.

      Torque:
      Nut, Bolt
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }
    3. B0069P9

      Connect the connector.

  3. INSTALL SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the suction hose sub-assembly and connecting part of the compressor assembly with pulley.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. B006DZB

      Install the suction hose sub-assembly to the compressor assembly with pulley with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note


      • Do not apply excessive force to the suction hose sub-assembly.

      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

  4. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the discharge hose sub-assembly and connecting part of the compressor assembly with pulley.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the discharge hose sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. B006E9Q

      Connect the discharge hose sub-assembly to the compressor assembly with pulley with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note


      • Do not apply excessive force to the discharge hose sub-assembly.

      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

  5. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY (for Bank 2)

    Click here

  6. INSTALL NO. 2 AIR TUBE ASSEMBLY

    Click here

  7. INSTALL AIR CLEANER SUPPORT BRACKET ASSEMBLY


    1. B006BRL

      Install the air cleaner support bracket assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  8. INSTALL NO. 13 CONNECTOR HOLDER


    1. B006A41C01
      *a Clamp
      *b Guide

      Attach the clamp to install the No. 13 connector holder to the air cleaner support bracket assembly.

    2. Connect the connector.

  9. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the suction hose sub-assembly and air conditioning tube and accessory assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. B006CWX

      Connect the suction hose sub-assembly to the air conditioning tube and accessory assembly with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note


      • Do not apply excessive force to the suction hose sub-assembly and air conditioning tube and accessory assembly.

      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

  10. INSTALL AIR CLEANER WITH ELEMENT ASSEMBLY RH

    Click here

  11. INSTALL AIR CLEANER WITH ELEMENT ASSEMBLY LH

    Click here

  12. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH


    1. B006EKY

      Install the radiator support to crossmember brace sub-assembly RH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  13. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH


    1. B006GYK

      Install the radiator support to crossmember brace sub-assembly LH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  14. INSTALL FAN AND GENERATOR V BELT

    Click here

  15. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  16. ADD ENGINE COOLANT

    Click here

  17. INSPECT FOR COOLANT LEAK

    Click here

  18. WARM UP ENGINE

    Click here

  19. INSPECT FOR REFRIGERANT LEAK

    Click here

  20. INSTALL OIL PAN PROTECTOR

    Click here

  21. CONNECT NO. 1 ENGINE UNDER COVER ASSEMBLY

    Click here

  22. INSTALL LOWER RADIATOR AIR DEFLECTOR

    Click here

  23. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  24. INSTALL RADIATOR COVER PLATE

    Click here

  25. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here