COMPRESSOR(for 2GR-FE) INSTALLATION

PROCEDURE


  1. ADJUST COMPRESSOR OIL


    1. When replacing the compressor with a new one:


      1. A002BLIC01
        *a Drain Bolt (Seal Washer)

        Remove the drain bolt (seal washer).

      2. A0026WYC07
        *a Removed Compressor
        *b Amount of oil to be drained from removed compressor
        *c Amount of oil remaining in the reserve chamber (60 cc (2.03 fl.oz))

        Gradually discharge the inert gas from the service valve. Then drain the following amount of oil from the new compressor before installation so that the amount of oil contained in it is the same as that in the compressor to be replaced.

        Tech Tips

        New compressors are filled with sufficient oil for the whole air conditioning system. Therefore, it is necessary to drain oil from the new compressor to compensate for oil remaining in the condenser and cooling unit.

        Standard
        (The amount of compressor oil inside a new compressor assembly with pulley: 120 (+15) cc (4.06 (+0.51) fl.oz)) - (The amount of compressor oil remaining in the removed compressor assembly with pulley) = The amount of compressor oil to be removed when replacing the compressor assembly with pulley.

        Note


        • When A + 60 cc (2.03 fl.oz) exceeds the standard oil fill volume specified for the compressor by part number, install the compressor without adjusting the oil volume.

          Example:

          If A = 45 cc (1.52 fl.oz), A + 60 cc (2.03 fl.oz) = 105 cc (3.55 fl.oz). If the standard volume is 120 cc (4.06 fl.oz), install the compressor as is.

        • If the amount of compressor oil remaining in the removed compressor assembly with pulley is too low, check for compressor oil leaks.

        • Make sure to use ND-OIL 8 or equivalent compressor oil.

      3. Install the drain bolt (seal washer).

        Torque:
        30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    2. If draining the oil is difficult, drain the oil using the following procedure:


      1. Remove the suction seal cap.

      2. A018KTR

        Lightly shake the compressor with the suction port facing down, and drain the oil (*1).

        Note

        Do not allow the pulley to come into contact with the compressor oil.

    3. A018HS7

      With the pulley facing down, rotate the hub as shown in the illustration 10 times at a rate of approximately once every 2 seconds (*2).

      CAUTION:

      If the pulley is rotated, refrigerant or oil may spray out. Thus, keep your face away from the compressor port.

    4. A018M4Q

      Rotate the hub once as shown in the illustration while quickly turning the compressor with the pulley facing up (*3).

    5. Perform step (*1) and drain the oil (*4).

    6. Drain the oil by repeating steps (*2) to (*4) approximately 5 times.

  2. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY


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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A002AMJC02
      B003ZIE Bolt
      B003Z8F Nut

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

      Torque:
      24.5 N*m  { 250 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 each 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 suction hose sub-assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

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

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to 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. INSTALL RADIATOR ASSEMBLY

    Click here

  7. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  8. WARM UP ENGINE

    Click here

  9. INSPECT FOR REFRIGERANT LEAK

    Click here