COMPRESSOR INSTALLATION

TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH
1. Temporarily install the compressor and magnetic clutch with the 3 bolts.
  
  Tech Tips
  
  Temporarily tighten the bolts in the order shown in the illustration.
INSTALL COMPRESSOR AND MAGNETIC CLUTCH
1. Install the compressor and magnetic clutch with the 4 bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.
2. Engage each clamp.
3. Connect each connector.
CONNECT SUCTION HOSE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the hose.
2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring onto the suction hose sub-assembly.
4. Install the suction hose sub-assembly onto the compressor and magnetic clutch with the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
CONNECT DISCHARGE HOSE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the hose.
2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring onto the discharge hose sub-assembly.
4. Install the discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
INSTALL RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR

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INSTALL V-RIBBED BELT

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CHARGE WITH REFRIGERANT
1. Perform vacuum purging using a vacuum pump.
2. Charge with refrigerant HFC-134a (R134a).
  
  Standard (w/o Rear Air Conditioning System)
  
  550 to 650 g (19.4 to 22.9 oz.)
  
  Standard (w/ Rear Air Conditioning System)
  
  720 to 820 g (25.4 to 28.9 oz.)
  
  SST
  
  09985-20010 ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )
  Note
  
  Do not turn the A/C on before charging with refrigerant. Doing so will cause the cooler compressor to work without refrigerant, resulting in overheating of the cooler compressor.
  
  Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.
  Tech Tips
  
  Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an A/C system.
WARM UP ENGINE
1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.
  
  Note
  
  Be sure to warm up the compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.
INSPECT FOR REFRIGERANT LEAK
1. After recharging with refrigerant gas, inspect for refrigerant leak using a halogen leak detector.
2. Carry out the test under the following conditions:
  - Make sure that the ignition switch is off.
  - 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. Using a gas leak detector, inspect for refrigerant leak from the refrigerant lines.
4. Bring the gas leak detector close to the drain hose with the detector's power off, and then turn the detector on.
  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 it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing.
5. If a gas leak is not detected from the drain hose, remove the blower motor from the cooling unit. Insert the gas leak detector 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.