COMPRESSOR (for AD Series Engine) INSTALLATION


  1. ADJUST AMOUNT OF COMPRESSOR OIL

    A01IO2W

    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)
      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. 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. A01IQIH

      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. A01IT5M

      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 approximately 5 times to drain the standard amount of oil.

  2. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY


    1. A01IRHZ

      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. A01IOO2E01

      Install the 2 bolts and 2 nuts.

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

      Tech Tips

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

    3. A01IRAM

      Connect the connector.

  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 to the suction hose sub-assembly.

    4. A01IPZC

      Connect the suction hose sub-assembly to 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 to the discharge hose sub-assembly.

    4. A01IQA7

      Connect the discharge hose sub-assembly to the compressor assembly with pulley with the bolt.

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

  5. CONNECT NO. 3 AIR HOSE


    1. A01IQND

      Connect the No. 3 air hose.

    2. Tighten the hose clamp of the No. 3 air hose.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  6. INSTALL FAN AND GENERATOR V BELT


    1. for 1AD-FTV:

      Install the V-ribbed belt Click here.

    2. for 2AD-FHV:

      Install the V-ribbed belt Click here.

  7. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A01INC5E01

      Install the front suspension member reinforcement RH with the 4 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration.

  8. INSTALL REAR ENGINE UNDER COVER RH


    1. A01IQ51

      Remove the 5 clips and under cover.

  9. INSTALL NO. 1 ENGINE UNDER COVER


    1. A01IRQL

      Install the No. 1 engine under cover with the 10 clips and 6 bolts.

  10. INSTALL FRONT LOWER BUMPER ABSORBER


    1. A01IPJ8

      Insert the 2 hooks of the front lower bumper absorber into the installation holes in the body to install the front lower bumper absorber.

    2. Install the 4 bolts.

    3. A01IOQE

      Install the 2 clips.

  11. 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)
      A01IS7RE26

      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 measuring its quantity, and not with the sight glass.

  12. 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 by turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.

  13. CHECK FOR REFRIGERANT 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. A01IPCYE30
      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.

  14. INSTALL RADIATOR SUPPORT OPENING COVER


    1. A01IRWC

      Install the radiator support opening cover with the 5 clips.

  15. INSTALL BATTERY SERVICE HOLE COVER


    1. A01ITOM

      Install the battery service hole cover with the clip.

  16. INSTALL NO. 1 ENGINE COVER


    1. A01INMI

      Attach the 4 clips to install the No. 1 engine cover.