COMPRESSOR(for 2ZR-FE) INSTALLATION

PROCEDURE


  1. INSPECT 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 a refrigeration failure.

      • 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 too low, check for compressor oil leakage.

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

      • Make sure to use ND-OIL 12 or equivalent compressor oil.

    2. B0046H0

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

    3. B00467LC01
      *a Oil port
      *b Turn clockwise

      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.

    4. B0046H0

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

      Tech Tips

      The drain bolt (seal washer) can be reused.

    5. B00467LC01
      *a Oil port
      *b Turn clockwise

      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 cc (2.37 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 condenser with receiver assembly is also replaced, do not add the specified amount of oil for condenser with receiver assembly replacement (40 cc (1.35 fl.oz.)).

    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 WITH PULLEY ASSEMBLY


    1. Using a "TORX" socket wrench (E8), install the compressor with pulley assembly with the 2 stud bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. B00483PE01

      Install the 2 bolts and 2 nuts.

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

      Torque:
      Bolt
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Nut
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  3. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the attached vinyl tape from the No. 1 cooler refrigerant discharge hose.

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

      Compressor oil
      ND-OIL 12 or equivalent

    3. Install the O-ring onto the No. 1 cooler refrigerant discharge hose.

    4. Install the discharge hose onto the compressor with pulley assembly with the bolt.

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

  4. CONNECT SUCTION HOSE SUB-ASSEMBLY


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

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

      Compressor oil
      ND-OIL 12 or equivalent

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

    4. Install the suction hose onto the compressor with pulley assembly with the bolt.

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

    5. Connect the connector.

  5. INSTALL ENGINE UNDER COVER RH

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  6. INSTALL ENGINE UNDER COVER LH

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  7. INSTALL FAN AND GENERATOR V BELT

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  8. CHARGE REFRIGERANT

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  9. WARM UP ENGINE

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  10. INSPECT FOR REFRIGERANT LEAK

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