COMPRESSOR (for ZR Series Engine) INSTALLATION


  1. ADJUST AMOUNT OF COMPRESSOR OIL


    1. When replacing the compressor assembly with a new one:

      Drain the following amount of compressor oil from the new compressor to be installed to adjust the amount of compressor oil.

      Standard (Amount of oil to be drained when replacing)
      50 cc (1.7 fl.oz)

      Note


      • Since compressor oil remains in the pipes of the vehicle, if a new compressor is installed without removing some oil from the compressor, the oil amount becomes excessive. Excessive oil prevents heat exchange in the refrigerant cycle and causes refrigeration system failure.

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


      1. Discharge the inert gas (helium) from the service valve.

      2. Remove the suction seal cap.

      3. A00OI91

        Position the suction port downward and slightly shake the compressor to drain oil.*1

        Note

        Be careful not to allow compressor oil to adhere to the pulley.

    2. A00OM5G

      Position the pulley side downward and turn the pulley in the direction indicated by the arrow once every 2 seconds 10 times.*2

      Note

      Keep your face away from the compressor port because turning the pulley may cause gas or oil to spew out.

    3. A00OJSH

      Quickly position the pulley side upward and turn the pulley in the direction indicated by the arrow once.*3

    4. Repeat procedure *1.*4

    5. Repeat procedures *2 through *4 about 5 times to drain the standard amount of oil.

  2. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY


    1. A00OO0Y

      Using a "TORX" socket wrench (E8), install the compressor assembly with pulley with the 2 stud bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. A00OJFTE02

      Install the 2 bolts and 2 nuts.

      Tech Tips

      Tighten the bolts and nuts in the order shown in the illustration.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    3. A00ONPK

      Connect the connector.

    4. Attach the 2 clamps.

  3. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the hose and compressor.

    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 suction hose sub-assembly.

    4. A00OJTM

      Install the suction hose sub-assembly onto the compressor assembly with pulley 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 hose and compressor.

    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 discharge hose sub-assembly.

    4. A00ONS7

      Install the discharge hose sub-assembly onto the compressor assembly with pulley with the bolt.

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

  5. INSTALL V-RIBBED BELT


    1. for 1ZR-FAE:

      Install the V-ribbed belt Click here.

    2. for 2ZR-FAE:

      Install the V-ribbed belt Click here.

    3. for 3ZR-FAE:

      Install the V-ribbed belt Click here.

    4. for 3ZR-FE:

      Install the V-ribbed belt Click here.

  6. ADJUST V-RIBBED BELT


    1. for 1ZR-FAE:

      Adjust the V-ribbed belt Click here.

    2. for 2ZR-FAE:

      Adjust the V-ribbed belt Click here.

    3. for 3ZR-FAE:

      Adjust the V-ribbed belt Click here.

    4. for 3ZR-FE:

      Adjust the V-ribbed belt Click here.

  7. INSPECT V-RIBBED BELT


    1. for 1ZR-FAE:

      Inspect the V-ribbed belt Click here.

    2. for 2ZR-FAE:

      Inspect the V-ribbed belt Click here.

    3. for 3ZR-FAE:

      Inspect the V-ribbed belt Click here.

    4. for 3ZR-FE:

      Inspect the V-ribbed belt Click here.

  8. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A00OLXIE01

      Install the reinforcement with the 4 bolts.

      Torque:
      96 N*m  { 979 kgf*cm, 71 ft.*lbf }

      Note

      Tighten the bolts in the order of C, B, D and A.

  9. INSTALL REAR ENGINE UNDER COVER RH


    1. A00OMDF

      Install the under cover RH with the 5 clips.

  10. INSTALL NO. 1 ENGINE UNDER COVER (for Rough Road Area Specification Vehicles)


    1. A00OL2M

      Install the under cover with the 3 clips.

  11. INSTALL NO. 1 ENGINE UNDER COVER


    1. A00ON3U

      Install the under cover with the 10 clips.

  12. INSTALL FRONT LOWER BUMPER ABSORBER


    1. A00OI9A

      Install the front lower bumper absorber with the 3 screws and 8 bolts.

    2. A00OL3A

      Install the 4 screws and 2 bolts.

  13. 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
      440 +/-30 g (15.5 +/-1.1 oz)
      A00DTEOE26

      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.

  14. 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 on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.

  15. 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 observing the following instructions:


      • 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.

        Tech Tips

        When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A00DTQYE30
      Text in Illustration
      *1 Check for Leakage
      *2 Halogen Leak Detector

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.

    5. Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.

  16. INSTALL RADIATOR SUPPORT OPENING COVER


    1. A00OKW2

      Install the radiator support opening cover with the 7 clips.

  17. INSTALL NO. 2 CYLINDER HEAD COVER


    1. A00OIJQ

      Attach the 4 clips to install the cover.

      Note


      • Be sure to attach the clips securely.

      • Do not apply excessive force or hit the cover to attach the clips. This may cause the cover to break.