COMPRESSOR(for 2GR-FKS) INSTALLATION

PROCEDURE


  1. ADJUST COMPRESSOR OIL


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


      1. B004KBNC01
        *a Drain Bolt (Seal Washer)

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

      2. B004N2UC07
        *a Removed Compressor
        *b Amount of oil to be drained from removed compressor assembly with 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 assembly with 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
        (The amount of compressor oil inside a new compressor assembly with magnetic clutch: 70 (+15) cc (2.37 (+0.51) fl.oz)) - (The amount of compressor oil remaining in the removed compressor assembly with magnetic clutch) = The amount of compressor oil to be removed when replacing the compressor assembly with 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 assembly with magnetic clutch is excessively low, check for compressor oil leaks.

        • Make sure to use ND-OIL 8 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. B004KEG

        Lightly shake the compressor assembly with 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. B004IXY

      With the pulley facing down, rotate the pulley 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. B004MQM

      Rotate the pulley 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 ASSEMBLY WITH MAGNETIC CLUTCH


    1. for Type A:


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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. B00718HC02
        *a Bracket
        B006Z38 Bolt
        B006ZY0 Nut

        Install the compressor assembly with 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 assembly with magnetic clutch.

    2. for Type B:


      1. B004HFYC02
        *a Bracket

        Install the compressor assembly with 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 assembly with 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.

      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. Connect the suction hose sub-assembly to the compressor assembly with magnetic clutch with the bolt.

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

  4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the No. 1 cooler refrigerant discharge hose sub-assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 1 cooler refrigerant discharge hose sub-assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the No. 1 cooler refrigerant discharge hose sub-assembly.

      Note

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

    4. Connect the No. 1 cooler refrigerant discharge hose sub-assembly to the compressor assembly with 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

    Click here

  8. WARM UP ENGINE

    Click here

  9. INSPECT FOR REFRIGERANT LEAK

    Click here