1AR-FE COMPRESSOR INSTALLATION


  1. INSPECT COMPRESSOR OIL LEVEL


    1. A019KO7

      When replacing the cooler compressor assembly with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil from the vents indicated by the arrows in the illustration before installation.

      Tech Tips

      The drain bolt and washer can be reused.

      Standard
      (Volume of oil in the new compressor assembly with pulley: 100 + 15 cc (3.4 + 0.51 fl.oz.) ) - (Amount of oil remaining in the removed compressor assembly with pulley) = (Oil amount to be removed from the new compressor when replacing)

      Note


      • If a new compressor is installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be excessive. This prevents heat exchange in the refrigerant cycle and causes refrigeration system failure.

      • If the volume of oil remaining in the removed compressor is too small, check for oil leaks.

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

  2. TEMPORARILY TIGHTEN COMPRESSOR ASSEMBLY WITH PULLEY


    1. A019NURE01
      Text in Illustration
      *1 Stud bolt
      *2 Bolt

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

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

    2. Temporarily install the compressor assembly with pulley with the 2 stud bolts and 2 bolts.

  3. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY


    1. A019NGHE01

      Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

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

      Note

      Tighten the bolts and nuts in the order shown in the illustration to install the compressor assembly with pulley.

    2. A019OD6E02
      Text in Illustration
      *1 Nut
      *2 Bolt A
      *3 Bolt B

      Install the frame side plate RH with the 3 bolts and nut.

      Torque:
      Nut
      32 N*m  { 327 kgf*cm, 24 ft.*lbf }
      Bolt A
      32 N*m  { 327 kgf*cm, 24 ft.*lbf }
      Bolt B
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

  4. 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 compressor assembly with pulley.

      Compressor oil
      ND-OIL 8 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.

    4. 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. 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 compressor assembly with pulley.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring onto the suction hose sub-assembly.

      CAUTION:

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

    4. 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 }

    5. Engage the 2 clamps.

    6. Connect the 2 connectors.

  6. INSTALL V-RIBBED BELT


    1. A019N3FE03
      Text in Illustration
      *1 Generator
      *2 Tensioner
      *3 Crankshaft
      *4 Water Pump
      *5 Cooler Compressor

      Set the V-ribbed belt onto each part as shown in the illustration except the water pump pulley.

    2. Loosen the V-ribbed belt by turning the belt tensioner clockwise.

    3. Set the V-ribbed belt onto the water pump pulley.

      Note

      Make sure that the belt is attached to each pulley. In particular, make sure that the belt is securely fitted into the grooves of the crankshaft pulley.

  7. INSTALL FRONT FENDER APRON SEAL RH


    1. A019O37

      Install the front fender apron seal RH with the 2 bolts and clip.

  8. INSTALL FRONT FENDER LINER RH


    1. A019NHQE01
      Text in Illustration
      *1 Grommet

      Install 3 new grommets and 6 screws.

    2. Install the 7 clips.

    3. A019MAO

      Using a 4 mm hexagon wrench, install the front fender liner RH with the 4 hexagon screws.

    4. A019PEFE01
      Text in Illustration
      *1 Correct
      *2 Incorrect

      Install the 2 pin hold clips.

      Note

      Insert the pin hold with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is vertical.

  9. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  11. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A019MUNE05
      Standard (for Suction Pipe Separate Type)
      450 to 550 g (15.9 to 19.4 oz.)
      Standard (except Suction Pipe Separate Type)
      500 to 600 g (17.6 to 21.2 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 with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

      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.

  12. WARM UP ENGINE


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

  13. INSPECT FOR REFRIGERANT LEAK


    1. After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Turn the engine 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)

    3. A019KMKE31
      Text in Illustration
      *1 Inspect for Leak
      *2 Halogen Leak Detector

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

    4. A019MG9E08
      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.

    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 perform the test.

    6. 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.

  14. INSTALL NO. 1 ENGINE UNDER COVER