COOLER EXPANSION VALVE (for TMMK Made) INSTALLATION

INSTALL COOLER EXPANSION VALVE
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the cooler expansion valve.
  
  Compressor Oil
  
  ND-OIL 8 or equivalent
2. Install 2 new O-rings to the No. 1 cooler evaporator sub-assembly.
3. Using a 4 mm hexagon socket wrench, install the cooler expansion valve with the 2 hexagon bolts.
  
  Torque:
  
  3.5 N*m { 36 kgf*cm, 31 in.*lbf }
CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY
1. Remove the vinyl tape from the air conditioner tube and accessory assembly.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioner tube and accessory assembly.
  
  Compressor Oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring to the air conditioner tube and accessory assembly.
  
  Note
  
  Keep the O-ring and O-ring fitting surface free from dirt and foreign matter.
4. Connect the air conditioner tube and accessory assembly.
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 suction hose sub-assembly.
  
  Compressor Oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring to the suction hose sub-assembly.
  
  Note
  
  Keep the O-ring and O-ring fitting surface free from dirt and foreign matter.
4. Connect the suction hose sub-assembly.
5. Rotate the hook connector as shown in the illustration.
6. Insert the pipe joint into the fitting hole securely and install the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY
1. Install the front outer cowl top panel sub-assembly with the 10 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.
3. w/ Windshield Deicer System:
  1. Connect the connector.
  2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.
4. w/ Heated Windshield Defroster System:
  1. Connect the 2 connectors.
  2. Engage the 4 clamps to install the wire harness to the front outer cowl top panel sub-assembly.
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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Compressor Oil
ND-OIL 8 or equivalent

Compressor Oil
ND-OIL 8 or equivalent

Compressor Oil
ND-OIL 8 or equivalent

CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Perform vacuum purging using a vacuum pump or appropriate equipment.

Charge the air conditioning system with refrigerant.

Refrigerant type
HFC-134a (R134a)

Text in Illustration
*a	Standard Charge Amount	*b	Mean Value in Proper Range
*c	Overcharged	*d	High Pressure
*e	Sub-cool System	*f	Refrigerant Amount
*g	+/-50 g (+/-1.76 oz)	-	-

Standard charge amount
450 to 550 g (15.9 to 19.3 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 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.

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.

WARM UP ENGINE
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 any air conditioning system lines (including the compressor).

INSPECT FOR REFRIGERANT LEAK

After recharging the air conditioning system with refrigerant, inspect for refrigerant leaks using a halogen leak detector.
Carry out the test under the following conditions:
- Ignition 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)

Text in Illustration
*a	Inspect for Leak
*b	Halogen Leak Detector

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

Text in Illustration
*1	Drain Cooler Hose
*a	Halogen Leak Detector

Bring the halogen leak detector close to the drain cooler 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 cooler hose.
When bringing the halogen leak detector close to the drain cooler 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.

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