COMPRESSOR INSTALLATION

ADJUST COMPRESSOR OIL

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

Standard
(Oil capacity inside the new electric inverter compressor assembly: 120 to 135 cc (4.1 to 4.6 fl. oz.)) - (Remaining oil amount in the removed electric inverter compressor assembly) = (Oil amount to be removed from the new compressor when replacing)

Note

When checking the compressor oil level, observe the precautions on the cooler removal/installation.
If a new electric inverter compressor assembly are installed without removing some oil, there will be too much oil in the system due to the oil remaining in the pipes of the vehicle. Excessive oil in the system prevents heat exchange in the refrigeration cycle and causes refrigeration failure.
If the amount of oil remaining in the old electric inverter compressor assembly is too small, check the A/C system for oil leaks.
Be sure to use ND-OIL 11 or equivalent for compressor oil. If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

INSTALL ELECTRIC INVERTER COMPRESSOR ASSEMBLY
1. Install the bracket with the bolt to the electric inverter compressor assembly.
2. Text in Illustration
  
  *1 Bracket
  
  Install the electric inverter compressor assembly and bracket with the 3 bolts.
  
  Torque:
  
  25 N*m { 250 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration to install the electric inverter compressor assembly.
CONNECT DISCHARGE 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 electric inverter compressor assembly.
  
  Compressor oil
  
  ND-OIL 11 or equivalent
3. Install the O-ring onto the discharge hose sub-assembly.
  Note
  - Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.
  - Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
4. Install the discharge hose sub-assembly onto the electric inverter compressor assembly with the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
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 electric inverter compressor assembly.
  
  Compressor oil
  
  ND-OIL 11 or equivalent
3. Install the O-ring onto the suction hose sub-assembly.
  Note
  - Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.
  - Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
4. Engage the clamp.
5. Install the suction hose sub-assembly onto the electric inverter compressor assembly with the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
6. Text in Illustration
  
  *1 Green-colored Lock
  
  Engage each clamp.
7. Connect the connector <A> and lock the green-colored lock as shown in the illustration.
  
  CAUTION:
  
  Wear insulated gloves when performing the procedure.
8. Connect each connector <B>, <C>.
INSTALL RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR

Tech Tips

Refer to the procedure for Install No. 2 Radiator Assembly Click here.
INSTALL SERVICE PLUG GRIP
CAUTION:

Wear insulated gloves.

Note

Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.
1. Wear insulated gloves and insert the service plug grip in the order shown in the illustration.
2. Tilt the service plug grip 90° and slide it down until a click sound is heard.
INSTALL BATTERY SERVICE HOLE COVER
1. Engage the 2 clips, 2 guides and install the battery service hole cover.
  
  Note
  
  Make sure that the battery service hole cover is installed securely.
CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSTALL REAR DECK FLOOR BOX
1. Install the rear deck floor box with the 3 clips.
CHARGE WITH REFRIGERANT
1. Perform vacuum purging using a vacuum pump.
2. Charge with refrigerant HFC-134a (R134a).
  
  Standard
  
  550 to 650 g (19.4 to 22.9 oz.)
  
  SST
  
  09985-20010 ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )
  Note
  
  Do not turn the A/C on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the cooler compressor.
  
  Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.
  
  Avoid using the gauge manifold set that had been used for vehicles with conventional compressor oil (ND-OIL 8 or equivalent) as much as possible. This will cause compressor oil remaining in the manifold to enter the vehicle, resulting in insulation performance deterioration. A gauge manifold set that had been used 3 times or less can be reused if an appropriate one is not available.
  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.
WARM UP COMPRESSOR
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 on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

Text in Illustration
*1	Bracket

Compressor oil
ND-OIL 11 or equivalent

Compressor oil
ND-OIL 11 or equivalent

Text in Illustration
*1	Green-colored Lock

Standard
550 to 650 g (19.4 to 22.9 oz.)

INSPECT FOR REFRIGERANT LEAK

After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.
Carry out the test under the following conditions:
- Turn the power 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)

Text in Illustration
*1	Inspect for Leak
*2	Halogen Leak Detector

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

Text in Illustration
*1	Halogen Leak Detector
*2	Drain Hose

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.

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.
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.