COMPRESSOR INSTALLATION


  1. INSPECT COMPRESSOR OIL


    1. A01HSUK

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

      Standard
      (Oil capacity inside the new compressor with motor assembly: 120 to 135 cc (4.2 to 4.8 fl. oz.)) - (Remaining oil amount in the removed compressor with motor assembly) = (Oil amount to be removed from the new compressor)

      Note


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

      • If a new compressor with motor assembly is installed without removing some oil, there will be too much oil in the system due to the oil remaining in the pipes of the vehicle. Excessive oil in the system prevents heat exchange in the refrigeration cycle and causes ineffective cooling.

      • If the amount of oil remaining in the old compressor with motor assembly is too small, check the air conditioning system for oil leaks.

      • Be sure to use ND-OIL 11 or equivalent compressor oil. If any compressor oil other than ND-OIL 11 is used, compressor with motor assembly insulation performance may decrease, resulting in a leakage of electric power.

  2. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY


    1. Using an E8 "TORX" socket, and install the 2 stud bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01HTIBE01

      Install the compressor with motor assembly with the bolt and 2 nuts.

      Tech Tips

      Tighten the 2 bolts and nut in the order shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
    3. A01HT54E02
      Text in Illustration
      *1 Green-colored Lock

      Connect connector A and lock the green-colored lock as shown in the illustration.

    4. Connect connector B.

  3. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the hose.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

      Compressor oil
      ND-OIL 11 or equivalent

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

      Note


      • Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. Install the suction hose sub-assembly to the compressor with motor assembly with the bolt.

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

  4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the vinyl tape from the hose.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

      Compressor oil
      ND-OIL 11 or equivalent

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

      Note


      • Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. Install the No. 1 cooler refrigerant discharge hose to the compressor with motor assembly with the bolt.

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

  5. INSTALL RADIATOR ASSEMBLY

    Click here

  6. INSTALL SERVICE PLUG GRIP

    Click here

  7. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump or appropriate equipment.

    2. Charge the air conditioning system with refrigerant.

      Refrigerant type
      HFC-134a (R134a)
      A01HSHEE11
      Text in Illustration
      *a Sub-cool System *b High Pressure
      *c Refrigerant Amount *d Standard charge amount
      *e Charge additional 100g (3.5oz.) *f Point where bubbles disappear
      *g Mean value in proper range *h Overcharged
      Standard charge amount
      480 to 580g (16.9 to 20.4oz.)
      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 switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • The refrigerant amount should be checked by quantity (weight).

      • The graph above is shown for reference only. This vehicle is not equipped with a 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 air conditioning system.

  8. WARM UP COMPRESSOR


    1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

      Note

      To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

  9. INSPECT FOR REFRIGERANT LEAK


    1. After recharging the air conditioning system with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Turn the power switch off.

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

      • Repeat the inspection 2 or 3 times.

      • Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system.

        Pressure when the compressor is off: approx. 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi)

    3. A01HUA4E40
      Text in Illustration
      *1 Halogen Leak Detector
      *a Inspect for Leak

      Using a halogen leak detector, inspect for refrigerant leaks from the air conditioning system.

    4. A01HSWYE08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

      Bring the halogen leak detector close to the drain hose with the detector power off, and then turn the detector on.

      Tech Tips


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

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

      • When bringing the halogen leak detector close to the drain hose, make sure that the halogen 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 checking for leaks.

    5. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and check for a leak.

    6. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak.

      Tech Tips

      When checking for leaks, the presence of oily dirt at a joint can indicate a leak.