COMPRESSOR (for 1GR-FE) INSTALLATION

ADJUST COMPRESSOR OIL

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
GRJ200L-GNANKV, GNMNKV, GPANKV, GPMNKV
(Oil capacity inside the new compressor and magnetic clutch: 140 + 15 cc (4.7 + 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)
Except GRJ200L-GNANKV, GNMNKV, GPANKV, GPMNKV
(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 for compressor oil.

INSTALL COOLER COMPRESSOR ASSEMBLY
1. Install the cooler compressor with the 3 bolts.
  
  Torque:
  
  24.5 N*m { 250 kgf*cm, 18 ft.*lbf }
  
  Tech Tips
  
  Tighten the bolts in the order shown in the illustration.
2. Connect the connector.
CONNECT SUCTION HOSE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the 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 2 bolts.
  
  Torque:
  
  for bolt A
  
  9.8 N*m { 100 kgf*cm, 87 ft.*lbf }
  
  for bolt B
  
  24.5 N*m { 250 kgf*cm, 18 ft.*lbf }
CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
1. Remove the attached vinyl tape from the 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 cooler refrigerant discharge hose.
4. Connect the cooler refrigerant discharge hose to the cooler compressor with the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }

Compressor oil
ND-OIL 8 or equivalent

Compressor oil
ND-OIL 8 or equivalent

INSTALL FAN & GENERATOR V BELT

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

Set the V belt onto every part.

While turning the belt tensioner counterclockwise, remove the pin.

Note

Make sure that the V belt is properly installed to each pulley.
Check that the belt fits properly in the ribbed grooves.

Tech Tips

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

INSTALL FRONT FENDER APRON SEAL LH
1. Install the seal with the 4 clips.

CHARGE REFRIGERANT

SST: 09985-20010 ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

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 Rear Cooler	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/ Rear Cooler	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 Rear Cooler	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/ Rear Cooler	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.

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.
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. 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.
INSTALL UPPER RADIATOR SUPPORT SEAL
1. Install the radiator support seal with the 7 clips.