COMPRESSOR (for 2AR-FSE) INSTALLATION


  1. INSPECT COMPRESSOR OIL


    1. A01FTSK

      When replacing the compressor with motor assembly with a new one, gradually discharge the inert 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 a new compressor with motor assembly: 120 to 135 cc (4.1 to 4.5 fl. oz.)) - (Remaining oil amount in the removed compressor with motor assembly) = Oil amount to be removed from the new compressor with motor assembly.

      Note


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

      • If a new compressor with motor assembly is installed without removing some oil remaining in the pipes of the vehicle, the oil amount becomes excessive. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure.

      • If the volume of oil remaining in the removed compressor with motor assembly and magnetic clutch is too small, check for oil leakage.

      • Be sure to use ND-OIL 11 for compressor oil.

  2. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY


    1. Using an E8 ''TORX'' socket wrench, install the compressor with motor assembly with the stud bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01FRZLE01

      Install the 2 bolts and nut, and then tighten the 2 bolts and nut in the order shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    3. Connect the motor control connector.

    4. A01FQPKE01
      Text in Illustration
      *1 Connector Lock

      Connect the motor drive connector.


      1. Connect the connector, and then push in the connector lock as shown in the illustration to lock it securely.

        CAUTION:

        Make sure to wear insulating gloves.

        Note

        Make sure that the connector is connected securely.

  3. CONNECT NO. 1 HYBRID WATER PUMP OUTLET PIPE


    1. Connect the No. 1 hybrid water pump outlet pipe to the engine with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the attached vinyl tape from the No. 1 cooler refrigerant discharge hose.

    2. Apply sufficient compressor oil (ND-OIL 11) 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 to the No. 1 cooler refrigerant discharge hose.

    4. Connect the No. 1 cooler refrigerant discharge hose to the compressor with motor assembly with the bolt.

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

  5. CONNECT SUCTION HOSE


    1. Remove the attached vinyl tape from the suction hose.

    2. Apply sufficient compressor oil (ND-OIL 11) 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 to the suction hose.

    4. Connect the suction hose to the compressor with motor assembly with the bolt.

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

  6. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the screw.

  7. INSTALL ENGINE UNDER COVER


    1. Install the engine under cover with the 13 screws and 3 clips.

  8. INSTALL SERVICE PLUG GRIP

    Click here

  9. 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)
      A01FRAGE11
      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
      for 2GR-FXE
      450 to 550 g (15.9 to 19.4 oz.)
      for 2AR-FSE
      520 to 620 g (18.3 to 21.8 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 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

      Make sure 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.

  10. 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).

  11. CHECK FOR REFRIGERANT LEAK


    1. After recharging the air conditioning system with refrigerant, check 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. A01FR94E40
      Text in Illustration
      *1 Halogen Leak Detector
      *a Check for Leak

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

    4. 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.

    5. 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.

  12. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Put the engine in inspection mode Click here.

    2. Start the engine. Make sure that no oil leaks from the connection point of the oil filter cap.

  13. INSTALL ENGINE ROOM SIDE COVER


    1. Install the engine room side cover with the 4 clips.