COMPRESSOR (for 1KD-FTV, 2KD-FTV) INSTALLATION


  1. ADJUST COMPRESSOR OIL


    1. When replacing the compressor and magnet clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnet clutch before installation.

      Standard
      (Oil capacity inside the new compressor and magnet clutch: 80 + 15 cc (2.71 + 0.51 fl.oz)) - (Remaining oil amount in the removed compressor and magnet clutch) = (Oil amount to be removed from the new compressor)

      Note


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

      • If a new compressor and magnet clutch is installed without removing the oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure.

      • If the volume of oil remaining in the removed compressor and magnet clutch is small, check for oil leakage.

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

  2. INSTALL COOLER COMPRESSOR ASSEMBLY

    A01E09IE01

    1. Install the cooler compressor assembly with the 4 bolts and tighten the bolts in the order shown in the illustration.

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

    2. Connect the connector.

  3. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


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

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the No. 1 cooler refrigerant discharge hose.

    4. Connect the No. 1 cooler refrigerant discharge hose with the bolt.

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

  4. INSTALL SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape attached to the suction hose sub-assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor.

      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 with the bolt.

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

  5. INSTALL FAN AND GENERATOR V BELT


    1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.

      Note

      Make sure that the fan and generator V belt is set properly on each pulley.

    2. Check that the indicator mark of the V-ribbed belt tensioner Click here.

  6. INSTALL AIR CLEANER ASSEMBLY


    1. w/ EGR Cooler:

      Click here

    2. w/o EGR Cooler:

      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
      450 +- 30 g (15.87 +- 1.05 oz.)
      A01DWS4E02

      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 quantity, and not with the sight glass.

  8. WARM UP ENGINE


    1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.

      Note

      After removing and installing the cooler refrigerant lines (with the compressor), be sure to warm up the compressor when turning the A/C switch ON. This is done to prevent damage to the compressor.

  9. CHECK FOR LEAKAGE OF REFRIGERANT


    1. After recharging the refrigerant gas, prepare the vehicle for a refrigerant gas leakage check by making sure the following conditions are met.


      • The ignition switch is OFF.

      • The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases. If volatile gases are unavoidable, the vehicle must be lifted up.

      • Some refrigerant is remaining in the refrigerant system.

      • The compressor is OFF and its pressure is approximately 392 to 588 kPa (4 to 6 kgf/cm2).

    2. A01DWJCE03

      Check for refrigerant gas leakage from the refrigerant line.


      1. After the blower motor stops, wait at least 15 minutes.

      2. Using a gas leak detector, check that gas is not leaking from the refrigerant line. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    3. Check for refrigerant gas leakage from the cooling unit.


      1. Hold the gas leak detector so that the sensor is under the drain hose, as shown in the illustration.

      2. Check that gas is not leaking from the drain hose. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    4. Check for refrigerant gas leakage from the cooling unit.


      1. Remove the blower motor control from the unit. Insert the gas leak detector's sensor into the unit.

      2. Check that gas is not leaking from the unit. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    5. Check for refrigerant gas leakage from the pressure switch.


      1. Disconnect the pressure switch connector and wait approximately 20 minutes.

      2. Using a gas leak detector, check that gas is not leaking from the pressure switch. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    6. Repeat all steps above 2 to 3 times.