COMPRESSOR (for 1WW) INSTALLATION


  1. ADJUST AMOUNT OF COMPRESSOR OIL


    1. A01ISV4

      When replacing the compressor assembly with a new one:

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

      Standard (Amount of oil to be drained)
      90 to 105 cc (3.0 to 3.6 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. A01IUCZ

      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. A01IPTH

      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. A01IPDAE01
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced hammer, tap in a new compressor pin.

      Standard protrusion height
      3.5 to 4.5 mm (0.138 to 0.177 in.)

    2. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    3. A01INLAE01

      Install the bolt 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.

    4. Connect the connector and attach the harness clamp.

  3. 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. 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 }

  4. 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. 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 }

  5. INSTALL FAN AND GENERATOR V BELT

    Click here

  6. INSTALL RADIATOR ASSEMBLY

    Click here

  7. 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.

  8. 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.

  9. INSPECT FOR COOLANT LEAK


    1. Remove the reservoir cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the reservoir cap while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

    2. Fill the radiator assembly with coolant, and then attach a radiator cap tester.

    3. Warm up the engine.

    4. Pump the radiator cap tester to 143 kPa (1.5 kgf/cm2, 20.7 psi), and then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leakage.

      If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

    5. Reinstall the reservoir cap.

  10. 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.