COMPRESSOR INSTALLATION


  1. ADJUST COMPRESSOR OIL


    1. A00434R

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

      Standard
      (Oil capacity inside the new compressor with motor assembly: 130 to 145 cc (4.4 to 4.9 fl. oz.)) - (Remaining oil amount in the removed compressor with motor 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 compressor and magnetic clutch 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 compressor and magnetic clutch 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.

  2. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY


    1. Temporarily install the compressor with motor assembly with the 3 bolts.

    2. A004388E02

      Install the compressor with motor assembly 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 compressor with motor assembly.

    3. A0043AZE01
      Text in Illustration
      *1 Green-colored Lock

      Connect the connector <B>.

    4. Connect the connector <A> and lock the green-colored lock as shown in the illustration.

      CAUTION:

      Make sure to wear insulating gloves.

      Note

      Make sure that the connector is connected securely.

  3. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the suction hose sub-assembly.

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

      • 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 suction hose sub-assembly onto the compressor with motor assembly with the bolt.

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

  4. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the discharge hose sub-assembly.

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

      • 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 compressor with motor assembly with the bolt.

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

  5. INSTALL SERVICE PLUG GRIP

    Click here

  6. INSTALL NO. 1 ENGINE UNDER COVER

  7. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  8. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump or appropriate equipment.

    2. Charge the air conditioning system with refrigerant.

      Refrigerant type
      HFC-134a (R134a)
      A0043LPE11
      Text in Illustration
      *a Sub-cool System *b High Pressure
      *c Refrigerant Amount *d Standard charge amount
      *e Charge additional 100 g (3.5 oz.) *f Point where bubbles disappear
      *g Mean value in proper range *h Overcharged
      Standard charge amount
      440 to 500g (15.5 to 17.6oz.)
      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 switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • The refrigerant amount should be checked by quantity (weight).

      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 air conditioning system.

  9. WARM UP COMPRESSOR


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

      Note

      To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

  10. INSPECT FOR REFRIGERANT LEAK


    1. After recharging the air conditioning system with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Power switch off.

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

      • Repeat the inspection 2 or 3 times.

      • Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system.

        Pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm2, 57 to 85 psi)

    3. A0043GFE40
      Text in Illustration
      *1 Halogen Leak Detector
      *a Inspect for Leak

      Using a halogen leak detector, inspect for refrigerant leaks from the air conditioning system.

    4. A004341E08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

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

      Tech Tips


      • After the blower motor has stopped, leave the cooling unit 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 checking for leaks.

    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 check for a leak.

    6. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak.

      Tech Tips

      When checking for leaks, the presence of oily dirt at a joint can indicate a leak.