COMPRESSOR(for 2GR-FKS) INSTALLATION

PROCEDURE


  1. ADJUST COMPRESSOR OIL


    1. When replacing the compressor and magnetic clutch with a new one:


      1. B005N7TC01
        *a Drain Bolt (Seal Washer)

        Remove the drain bolt (seal washer) from a new compressor and magnetic clutch.

      2. B005N7OC07
        *a Removed Compressor
        *b Amount of oil to be drained from removed compressor and magnetic clutch
        *c Amount of oil remaining in the reserve chamber (60 cc (2.03 fl.oz))

        Gradually discharge the inert gas from the service valve of the new compressor and magnetic clutch. Then drain the following amount of oil from the new compressor before installation so that the amount of oil contained in it is the same as that in the compressor to be replaced.

        Tech Tips

        New compressors are filled with sufficient oil for the whole air conditioning system. Therefore, it is necessary to drain oil from the new compressor to compensate for oil remaining in the condenser and cooling unit.

        Standard (w/o Rear Air Conditioning System)
        (The amount of compressor oil inside a new compressor and magnetic clutch: 70 (+15) cc (2.37 (+0.51) fl.oz)) - (The amount of compressor oil remaining in the removed compressor and magnetic clutch) = The amount of compressor oil to be removed when replacing the compressor and magnetic clutch.
        Standard (w/ Rear Air Conditioning System)
        (The amount of compressor oil inside a new compressor and magnetic clutch: 120 (+15) cc (4.06 (+0.51) fl.oz)) - (The amount of compressor oil remaining in the removed compressor and magnetic clutch) = The amount of compressor oil to be removed when replacing the compressor and magnetic clutch.

        Note


        • When A + 60 cc (2.03 fl.oz) exceeds the standard oil fill volume specified for the compressor by part number, install the compressor without adjusting the oil volume.

          Example:

          If A = 45 cc (1.52 fl.oz), A + 60 cc (2.03 fl.oz) = 105 cc (3.55 fl.oz). If the standard volume is 70 (+15) cc (2.37 (+0.51) fl.oz)), install the compressor as is.

        • If the amount of compressor oil remaining in the removed compressor and magnetic clutch is excessively low, check for compressor oil leaks.

        • for HFC-134a (R134a): Make sure to use ND-OIL 8 or equivalent compressor oil.

        • for HFO-1234yf (R1234yf): Make sure to use ND-OIL 12 or equivalent compressor oil.

      3. Install the drain bolt (seal washer).

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

    2. If draining the oil is difficult, drain the oil using the following procedure:


      1. Remove the suction seal cap.

      2. B005L7Z

        Lightly shake the compressor and magnetic clutch with the suction port facing down, and drain the oil (*1).

        Note

        Do not allow the pulley to come into contact with the compressor oil.

    3. B005PA3

      With the pulley facing down, rotate the pully as shown in the illustration 10 times at a rate of approximately once every 2 seconds (*2).

      CAUTION:

      If the pulley is rotated, refrigerant or oil may spray out. Thus, keep your face away from the compressor port.

    4. B005OJ5

      Rotate the pully once as shown in the illustration while quickly turning the compressor up (*3).

    5. Perform step (*1) and drain the oil (*4).

    6. Drain the oil by repeating steps (*2) to (*4) approximately 5 times.

  2. INSTALL COMPRESSOR AND MAGNETIC CLUTCH


    1. for Type A:


      1. Using an E8 "TORX" socket wrench, temporarily install the compressor and magnetic clutch with the 2 stud bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. B005Q7YC02
        *a Bracket
        B005NIZ Bolt
        B005LWS Nut

        Install the compressor and magnetic clutch and bracket with the 2 bolts and 2 nuts.

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

        Tech Tips

        Tighten the bolts and nuts in the order shown in the illustration to install the compressor and magnetic clutch.

    2. for Type B:


      1. B005LYOC02
        *a Bracket

        Install the compressor and magnetic clutch and bracket with the 4 bolts.

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

        Tech Tips

        Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

    3. Engage each clamp.

    4. Connect each connector.

  3. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the suction hose sub-assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

      Refrigerant Compressor Oil
      HFC-134a (R134a) ND-OIL 8 or equivalent
      HFO-1234yf (R1234yf) ND-OIL 12 or equivalent

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

    4. Install the suction hose sub-assembly to the compressor and magnetic clutch with the bolt.

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

  4. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the discharge hose sub-assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the discharge hose sub-assembly.

      Refrigerant Compressor Oil
      HFC-134a (R134a) ND-OIL 8 or equivalent
      HFO-1234yf (R1234yf) ND-OIL 12 or equivalent

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

    4. Install the discharge hose sub-assembly to the compressor and magnetic clutch with the bolt.

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

  5. INSTALL RADIATOR ASSEMBLY

    Click here

  6. INSTALL V-RIBBED BELT

    Click here

  7. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    for HFC-134a (R134a):

    Click here

    for HFO-1234yf (R1234yf):

    Click here

  8. WARM UP ENGINE

    for HFC-134a (R134a):

    Click here

    for HFO-1234yf (R1234yf):

    Click here

  9. INSPECT FOR REFRIGERANT LEAK

    for HFC-134a (R134a):

    Click here

    for HFO-1234yf (R1234yf):

    Click here