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 8 or equivalent compressor oil.

    2. A012LMK

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

    3. A012IICC01
      *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. A012LMK

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

      Tech Tips

      The drain bolt (seal washer) can be reused.

    5. A012IICC01
      *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 ASSEMBLY WITH PULLEY


    1. A012IBPE01

      Using an E8 "TORX" socket, temporarily install the compressor assembly with pulley with the 2 stud bolts.

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

      Tech Tips

      Tighten the stud bolts in the order shown in the illustration to install the compressor assembly with pulley.

    2. A012GDVC06
      A012M0O Bolt
      A012L0C Nut

      Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

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

      Tech Tips

      Tighten the bolts and nuts in the order shown in the illustration to install the compressor assembly with pulley.

    3. Engage the clamp.

    4. Connect the connector.

  3. CONNECT SUCTION HOSE SUB-ASSEMBLY


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

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

      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 to the compressor assembly with pulley with the bolt.

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

  4. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the discharge hose sub-assembly.

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

      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 to the compressor assembly with pulley with the bolt.

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

  5. INSTALL V-RIBBED BELT

    Click here

  6. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  7. WARM UP ENGINE

    Click here

  8. INSPECT FOR REFRIGERANT LEAK

    Click here