COMPRESSOR (for 2AZ-FE) INSTALLATION


  1. ADJUST COMPRESSOR OIL LEVEL


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      When replacing the cooler compressor assembly with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil from the vents indicated by the arrows in the illustration before installation.

      Tech Tips

      The drain bolt and washer can be reused.

      Standard
      AC (Oil capacity inside the new compressor: 225 + 15 cc (7.6 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed from the new compressor when replacing)

      Note


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

      • If the volume of oil remaining in the removed compressor is too small, check for oil leaks.

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

  2. INSTALL COOLER COMPRESSOR BRACKET (w/o No. 2 Air Conditioning Tube)


    1. Install the cooler compressor bracket with the 2 bolts.

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

    2. connect the connector.

  3. TEMPORARILY TIGHTEN COMPRESSOR ASSEMBLY WITH PULLEY


    1. Using a "TORX" socket wrench (E8), install the compressor assembly with pulley with the stud bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  4. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/ No. 2 Air Conditioning Tube)


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      Install the compressor assembly with pulley with the 3 bolts and nut.

      Tech Tips

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

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    2. Connect the connector.

    3. Install the bracket with the bolt.

  5. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/o No. 2 Air Conditioning Tube)


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      Install the compressor assembly with pulley with the 3 bolts and nut.

      Tech Tips

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

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    2. Connect the connector.

    3. Engage the clamp.

  6. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the attached vinyl tape from the hose.

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

      Compressor oil
      ND-OIL 8 or equivalent

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

      Note

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

    4. Install the No. 1 cooler refrigerant discharge hose onto the compressor assembly with pulley with the bolt.

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

  7. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. Remove the attached vinyl tape from the hose.

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

      Compressor oil
      ND-OIL 8 or equivalent

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

      Note

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

    4. Install the No. 1 cooler refrigerant suction hose onto the compressor assembly with pulley with the bolt.

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

  8. INSTALL V-RIBBED BELT

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    Tech Tips

    The illustration shows the V-ribbed belt layout.


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      Using SST, slowly turn the V-ribbed belt tensioner clockwise and install the V-ribbed belt.

      SST
      09216-42010   ( 09216-04010 )

      Note


      • Make sure that SST and other tools are set to the tensioner securely.

      • When compressing the V-ribbed belt tensioner, slowly turn the tensioner.

  9. INSTALL RADIATOR RESERVE TANK BRACKET


    1. Install the radiator reserve tank bracket with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  10. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. Install the radiator reserve tank assembly to the radiator reserve tank bracket.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Connect the No. 1 and No. 2 water by-pass hoses.

    3. Connect the wire harness clamp to the radiator reserve tank assembly.

  11. INSTALL RADIATOR COVER SUB-ASSEMBLY


    1. Install the radiator cover sub-assembly with the 4 clips.

  12. INSTALL REAR ENGINE UNDER COVER RH

  13. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  14. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A01CBXEE04
      w/o No. 2 Air Conditioning Tube
      780 to 880 g (27.5 to 31.0 oz.)
      w/ No. 2 Air Conditioning Tube
      700 to 800 g (24.7 to 28.2 oz.)
      SST
      09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02140, 09985-02080 )

      Note


      • Do not turn the A/C switch on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • Approximately 200 g (7.1 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

      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 A/C system.

  15. WARM UP ENGINE


    1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

      Note

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

  16. INSPECT FOR REFRIGERANT LEAK


    1. After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Turn the engine switch off.

      • Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that there is some refrigerant remaining in the refrigeration system.

        When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

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      Using a halogen leak detector, inspect for refrigerant leaks from the refrigerant lines.

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      Bring the halogen leak detector close to the drain hose with the detector's power off, and then turn the detector on.

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring the halogen leak detector sensor under the drain hose.

      • When bringing the halogen leak detector close to the drain 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 testing.

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

    6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.