COMPRESSOR (for 2TR-FE) INSTALLATION


  1. ADJUST COMPRESSOR OIL


    1. When replacing the compressor and magnet 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 magnet clutch before installation.

      Standard
      (Oil capacity inside the new compressor and magnet clutch: 180 + 15 cc (6.08 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnet clutch) = (Oil amount to be removed from the new compressor)

      Note


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

      • If a new compressor and magnet clutch is installed without removing the 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 magnet clutch is small, check for oil leakage.

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

  2. INSTALL COOLER COMPRESSOR ASSEMBLY


    1. A01J4TOE01

      Install the compressor with the 4 bolts and tighten the bolts in the order shown in the illustration.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }
    2. A01J5P0

      Connect the connector.

  3. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A01J43A

      Remove the vinyl tape attached to the hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. Connect the discharge hose with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

  4. INSTALL SUCTION HOSE SUB-ASSEMBLY


    1. A01J6EM

      Remove the vinyl tape attached to the hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. Connect the suction hose with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

  5. INSTALL DRIVE BELT


    1. A01J3KGE04

      Install the drive belt to the pulleys except the drive belt tensioner pulley.

    2. Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and then install the drive belt to the tensioner pulley.

      Note


      • The backside of the drive belt should face the tensioner pulley.

      • Check that the drive belt is properly set to each pulley.

    3. A01J5HFE01

      After a new belt has been installed, check that the tensioner indicator mark is within range A shown in the illustration.

  6. CHARGE REFRIGERANT

    SST
    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. Charge refrigerant HFC-134a (R134a).

      Standard
      750 +-30 g (26.45 +-1.05 oz.)
      A01J472E02

      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 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

  7. WARM UP ENGINE


    1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.

      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.

  8. CHECK FOR LEAKAGE OF REFRIGERANT


    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 gas 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 to 6 kgf/cm2, 57 to 85 psi)

    3. A01J7J3E02

      Using a gas 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 gas leak detector sensor into the unit and perform the test.

    5. Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.