COMPRESSOR(except 3ZR-FE)

ADJUST AMOUNT OF COMPRESSOR OIL

When replacing the compressor assembly 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.
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 8 or equivalent compressor oil.

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

Text in Illustration
*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.

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

Tech Tips

The drain bolt (seal washer) can be reused.

Text in Illustration
*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 to 85 cc (2.37 to 2.87 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 oil for condenser with receiver assembly replacement (40 cc (1.35 fl.oz.)).

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.

INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

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

Torque:

9.8 N*m { 100 kgf*cm, 87 in.*lbf }
Install the 2 bolts and 2 nuts.

Tech Tips

Tighten the bolts and nuts in the order shown in the illustration.

Torque:

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

Text in Illustration

Bolt

Nut
Connect the connector.
Attach the clamp.

Text in Illustration
	Bolt
	Nut

CONNECT SUCTION HOSE SUB-ASSEMBLY

Remove the attached vinyl tape from the hose and compressor.
Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

Compressor oil

ND-OIL 8 or equivalent
Install the O-ring onto the suction hose sub-assembly.
Install the suction hose sub-assembly onto the compressor assembly with pulley with the bolt.

Torque:

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

Compressor oil
ND-OIL 8 or equivalent

CONNECT DISCHARGE HOSE SUB-ASSEMBLY

Remove the attached vinyl tape from the hose and compressor.
Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

Compressor oil

ND-OIL 8 or equivalent
Install the O-ring onto the discharge hose sub-assembly.
Install the discharge hose sub-assembly onto the compressor assembly with pulley with the bolt.

Torque:

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