COMPRESSOR AND PULLEY (for TR Series Engine) INSTALLATION


  1. ADJUST COMPRESSOR OIL


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

      Standard
      (Oil capacity inside the new compressor and pulley: 180 to 195 cc (6.3 to 6.9 fl. oz.)) - (Remaining oil amount in the removed compressor and pulley) = (Oil amount to be removed from the new compressor when replacing)

      Note


      • When checking the compressor oil level, observe the precautions on the cooler removal/installation.

      • If a new compressor and pulley installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and caused refrigerant failure.

      • If the volume of oil remaining in the removed compressor and pulley is too small, check for oil leakage.

      • Be sure to use ND-OIL 8 for compressor oil.

  2. TEMPORARILY TIGHTEN COMPRESSOR AND PULLEY


    1. A01BEDA

      Temporarily tighten the compressor and pulley with the 2 bolts.

  3. FULLY TIGHTEN COMPRESSOR AND PULLEY


    1. A01BBNSE01

      fully tighten the compressor and pulley with the 2 bolts.

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

      Note

      Tighten in the order indicated in the illustration.

  4. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1


    1. Remove the attached vinyl tape from the hose.

    2. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor and pulley.

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. A01BHQZ

      Install the cooler refrigerant discharge hose No.1 onto the compressor and pulley with the bolt.

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

  5. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1


    1. Remove the attached vinyl tape from the hose.

    2. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor and pulley.

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. A01BCYB

      Install the cooler refrigerant suction hose No.1 onto the compressor and pulley with the bolt.

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

  6. INSTALL OIL LEVEL GAUGE GUIDE


    1. A01BAN3E01

      Install the gauge guide with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  7. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY

  8. INSTALL FAN & GENERATOR V BELT

    A01BH2EE02

    1. Install the drive belt to the pulleys except the drive belt tensioner pulley.

    2. Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and then install the drive belt to the tensioner pulley.

      Note


      • The backside of the drive belt should face the tensioner pulley.

      • Check that the drive belt is properly set to each pulley.

    3. A01BENJE02

      After a new belt has been installed, check that the tensioner indicator mark is within range A shown in the illustration.

  9. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole sub cover with the 5 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  10. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  11. REMOVE FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  12. INSTALL FRONT DOOR SCUFF PLATE RH

  13. CHARGE REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A01BFDKE01
      Standard
      Single A/C
      520 to 580g (18.3 to 20.5 oz.)
      Dual A/C
      670 to 730g (23.0 to 25.7 oz.)
      SST
      07110-58060   ( 07117-58090, 07117-78050, 07117-58070, 07117-58060, 07117-58080, 07117-88060, 07117-88070, 07117-88080 )

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor does not work properly without any refrigerant, which causes the compressor to overheat.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

      Tech Tips

      Prepare a service can to recharge refrigerant if using the refrigerant gas collected with the freon collection/recycling device because the collective rate of the device is approximately 90%.

  14. WARM UP ENGINE


    1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.

      Note

      Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  15. CHECK FOR LEAKAGE OF REFRIGERANT


    1. After recharging refrigerant gas, check for leakage of refrigerant gas using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Stop the engine.

      • Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that there is some refrigerant remaining in the refrigeration system.

        When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A01BC1LE02

      Using a gas leak detector, check for leakage of the refrigerant line.

    4. A01BCXGE01

      Bring the gas leak detector close to the drain hose with the detector's power off.

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring the gas leak detector sensor under the drain hose.

      • When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.

        If such reaction is unavoidable, the vehicle must be lifted up.

    5. If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

    6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.