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COMPRESSOR (for 1UR-FE) INSTALLATION

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    ADJUST COMPRESSOR OIL


    1. When replacing the compressor and magnetic clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation.

      Standard
      (Oil capacity inside the new compressor and magnetic clutch: 135 + 15 cc (4.6 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing)
      Note:

      • When checking the compressor oil level, follow the A/C system precautions.

      • If a new compressor and magnetic clutch is installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure.

      • If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.

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

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    INSTALL COOLER COMPRESSOR ASSEMBLY


    1. Install the cooler compressor and stud bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Install the 3 bolts and nut.

      24.5 N*m 250 kgf*cm 18 ft.*lbf
      Tip:

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

    3. Connect the connector.

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    CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A015B9Y

      Remove the attached vinyl tape from the suction hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose.

    4. Connect the suction hose to the cooler compressor with the bolt.

      9.8 N*m 100 kgf*cm 87 in.*lbf
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    CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the attached vinyl tape from the cooler refrigerant discharge hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. Connect the discharge hose to the cooler compressor with the bolt.

      9.8 N*m 100 kgf*cm 87 in.*lbf
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    INSTALL FAN & GENERATOR V BELT


    1. A015BDAE04

      Set the fan and generator V belt onto every part.

      Table 1. Text in Illustration
      *1 Water Pump Pulley
      *2 Fan Pulley
      *3 No. 1 Idler Pulley
      *4 Vane Pump Pulley
      *5 Generator Pulley
      *6 V-ribbed Belt Tensioner
      *7 Crankshaft Pulley
      *8 Cooler Compressor Pulley

    2. While turning the belt tensioner counterclockwise, remove the pin.

      Note:

      Make sure that the fan and generator V belt is properly set on each pulley.

    3. Check that the belt fits properly in the ribbed grooves.

      Tip:

      Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of the pulley.

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    INSTALL FRONT FENDER APRON SEAL LH


    1. Install the seal with the 4 clips.

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    CHARGE REFRIGERANT

    09985-20010 09985-02130 09985-02150 09985-02090 09985-02110 09985-02010 09985-02050 09985-02060 09985-02070

    1. Perform vacuum purging using a vacuum pump.

    2. A015D7VE19

      Charge refrigerant HFC-134a (R134a).

      Table 2. Standard:
      Condenser Core Thickness Air Conditioning Type Cool Box Refrigerant Charging Amount
      22 mm (0.866 in.) w/o Rear Cooler w/ Cool Box 870 +/-30 g (30.7 +/-1.1 oz.)
      w/o Cool Box 870 +/-30 g (30.7 +/-1.1 oz.)
      w/ Rear Cooler w/ Cool Box 1010 +/-30 g (35.6 +/-1.1 oz.)
      w/o Cool Box 960 +/-30 g (33.9 +/-1.1 oz.)
      16 mm (0.630 in.) w/o Rear Cooler w/ Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)
      w/o Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)
      w/ Rear Cooler w/ Cool Box 970 +/-30 g (34.2 +/-1.1 oz.)
      w/o Cool Box 920 +/-30 g (32.5 +/-1.1 oz.)
      Note:

      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

      • Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

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    WARM UP ENGINE


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note:

      Be sure to warm up the compressor when turning the A/C switch is on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

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    CHECK FOR REFRIGERANT GAS LEAK


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation under these conditions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A015C1XE21

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

    5. Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

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    INSTALL UPPER RADIATOR SUPPORT SEAL


    1. A015BVKE02

      Install the radiator support seal with the 7 clips.