COMPRESSOR 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.

      • Do not race the engine before replacing the compressor assembly with pulley.

      • 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.

    2. B000U4V

      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.

      B000V2AC01
      *a Oil Port *b Turn Clockwise
    4. B000U4V

      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: 70 (+15) cc (2.37 (+0.51) 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 amount of compressor oil remaining in the removed compressor assembly with pulley cannot be estimated because the compressor was damaged and oil was discharged due to a frontal collision, etc., install the new compressor assembly with pulley without removing any oil. 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)).

      B000V2AC01
      *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. B000YEI

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. B000ULHC02
      B000XM7 Nut
      B000TT4 Bolt

      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. B000TZDC01
      *a Stopper
      B000XM7 Bolt (A)
      B000TT4 Connector
      B000YI8 bolt (B)

      Install the wiring harness clamp bracket (bolt (B) fastening side) with the bolt (B).

      Torque:
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }

    4. Install the wiring harness clamp bracket (bolt (A) fastening side) with the bolt (A).

      Note

      Install with a stopper on the seating surface of the compressor assembly with pulley.

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

    5. Connect the connector.

    6. Attach the clamp.

  3. CONNECT FRONT STABILIZER BAR

    Click here

  4. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    Click here

  5. CONNECT SUCTION HOSE SUB-ASSEMBLY A


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

      Note

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

    4. B000UW6

      Connect the suction hose sub-assembly A 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 A.

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

  6. 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
      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.

      Note

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

    4. B000V8C

      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)

  7. INSTALL AIR CLEANER SUPPORT BRACKET ASSEMBLY


    1. B000TZ5

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

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

    2. for RHD:


      1. B000WH5

        Attach the clamp to install the No. 10 connector holder to the air cleaner support bracket assembly.

      2. Connect the 2 connectors.

  8. INSTALL SUCTION HOSE SUB-ASSEMBLY A


    1. Remove the vinyl tape from the suction hose sub-assembly A and suction tube sub-assembly B.

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

      Compressor Oil
      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 A.

      Note

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

    4. B000Y1E

      Connect the suction hose sub-assembly A to the suction tube sub-assembly B 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 A and suction tube sub-assembly B.

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

  9. INSTALL FAN AND GENERATOR V BELT

    Click here

  10. INSTALL INTAKE AIR CONNECTOR PIPE


    1. Align the cutout of the intake air connector pipe with the protrusion of the intake air sound creator and connect the intake air connector pipe as shown in the illustration.

      Note

      Insert the intake air connector pipe until it hits the stopper.

      B000W7WC01
      *a Protrusion *b Cutout
      *c Stopper *d View A
      *e Positioning Stopper - -
      B000XM7 Bolt B000TT4 Intake Air Connector Pipe Hose Clamp

    2. Tighten the intake air connector pipe hose clamp as shown in the illustration.

      Note

      Install the intake air connector pipe hose clamp so that it contacts the intake air connector pipe positioning stopper.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Install the intake air connector pipe with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  11. INSTALL AIR (WITH ELEMENT) CLEANER ASSEMBLY WITH AIR CLEANER INLET

    Note

    Check that the air cleaner support is properly installed to the specified position on the air cleaner support bracket and upper radiator support.


    1. Install the air (with element) cleaner assembly with air cleaner inlet to the air cleaner support.

      B000YG4C01
      *1 Air Cleaner Support - -
      *a Clamp - -

    2. Attach the clamp as shown in the illustration.

      Installation Position
      Part Length
      A 310 mm (1.02 ft.)
      B 176 to 186 mm (6.9291 to 7.3228 in.)
      C 60.5 to 68.5 mm (2.3819 to 2.6968 in.)
    3. B000UGX

      Connect the connector.

    4. Attach the clamp.

    5. B000X9H

      Connect the 2 connectors.

    6. Attach the clamp.

    7. B000YHMC01
      *a Connector

      Connect the vacuum hose to the connector as shown in the illustration.

      Installation Position
      Part Length
      A 2 mm (0.0787 in.) or less.

    8. Install the vacuum hose to the guide.

  12. INSTALL AIR CLEANER HOSE ASSEMBLY

    Click here

  13. CONNECT NO. 2 PCV HOSE

    Click here

  14. CONNECT NO. 3 PCV HOSE

    Click here

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


    1. B000WHZ

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

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

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


    1. B000XDB

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

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

  17. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    for HFC-134a(R134a):

    Click here

    for HFO-1234yf(R1234yf):

    Click here

  18. WARM UP ENGINE

    for HFC-134a(R134a):

    Click here

    for HFO-1234yf(R1234yf):

    Click here

  19. INSPECT FOR REFRIGERANT LEAK

    for HFC-134a(R134a):

    Click here

    for HFO-1234yf(R1234yf):

    Click here

  20. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here