COMPRESSOR(for 2GR-FKS) INSTALLATION

PROCEDURE


  1. ADJUST COMPRESSOR OIL


    1. When replacing the compressor and magnet clutch 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 and magnet clutch 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 and magnet clutch 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 and magnet clutch is too low, check for compressor oil leakage.

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

    2. B006P20

      Remove the drain bolt (seal washer) from the removed compressor and magnet clutch.

    3. B006OK6

      Drain the compressor oil from the oil port of the removed compressor and magnet clutch as shown in the illustration and measure the removed oil as quantity B.

      Note


      • Make sure to drain the compressor oil from the oil port.

      • Keep your face away from the compressor port because turning the pulley may cause gas or oil to spray out.

    4. Calculate oil quantity C by subtracting oil quantity B, measured in the previous step, from oil quantity A (120 to 135 cc (4.06 to 4.56 fl.oz)), which is the amount of oil in a new compressor and magnet clutch.

      B006M5IC02
      *1 New Compressor and Magnet Clutch *2 Removed Compressor and Magnet Clutch
      *a Oil Quantity A (120 to 135 cc (4.06 to 4.56 fl.oz)) *b Oil Quantity B
      *c Oil Quantity C - -

      Tech Tips

      A new compressor and magnet clutch contains 120 to 135 cc (4.06 to 4.56 fl.oz) of compressor oil.

    5. Remove the drain bolt (seal washer) from a new compressor and magnet clutch, drain oil quantity C from the oil port, and use the amount of oil remaining in the compressor and magnet clutch as the standard value.

      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 and magnet clutch, make sure that it is free of foreign matter.

      • If the amount of compressor oil remaining in the removed compressor and magnet clutch cannot be estimated because the compressor was damaged and oil was discharged due to a frontal collision, etc., install the new compressor and magnet clutch 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.)).

    6. Install the drain bolt (seal washer) to the new compressor and magnet clutch.

      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.

      Tech Tips

      The drain bolt (seal washer) can be reused.

  2. INSTALL COMPRESSOR AND MAGNET CLUTCH


    1. B006Q1Y

      Using an E8 "TORX" socket wrench, temporarily install the compressor and magnet clutch with the 2 stud bolts.

    2. Tighten the 2 stud bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. B006LIPC02
      B006QOD Bolt
      B006LKF Nut

      While pushing the compressor and magnet clutch to the magnetic clutch assembly side, install the compressor and magnet clutch and wiring harness clamp bracket with the 2 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }
    4. B006O0J

      Install the wiring harness clamp bracket with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    5. B006MRR

      Attach the clamp.

    6. Connect the 3 connectors.

  3. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. B006NOA

      Remove the vinyl tape from the No. 1 cooler refrigerant suction hose and compressor and magnet clutch.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnet clutch.

      Compressor Oil
      ND-OIL 8 or equivalent

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

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Connect the No. 1 cooler refrigerant suction hose to the compressor and magnet clutch with the bolt.

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

  4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. B006N2P

      Remove the vinyl tape from the No. 1 cooler refrigerant discharge hose and compressor and magnet clutch.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnet clutch.

      Compressor Oil
      ND-OIL 8 or equivalent

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

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Connect the No. 1 cooler refrigerant discharge hose to the compressor and magnet clutch with the bolt.

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

  5. INSTALL RADIATOR ASSEMBLY

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  6. INSTALL FAN AND GENERATOR V BELT

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  7. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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  8. WARM UP ENGINE

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  9. INSPECT FOR REFRIGERANT LEAK

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