COMPRESSOR(for ZR Series Engine) INSTALLATION

PROCEDURE

  1. ADJUST AMOUNT OF COMPRESSOR OIL

    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.

      • for HFC-134a(R134a):

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

      • for HFO-1234yf(R1234yf):

        Be sure to use ND-OIL 12 for compressor oil.

      1. Discharge the inert gas (helium) from the service valve.

      2. Remove the suction seal cap.

      3. E143917

        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. E143918

      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. E143919

      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 about 5 times to drain the standard amount of oil.

  2. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

    1. E175927

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

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    2. U123699E01

      Install the 2 bolts and 2 nuts.

      Tip:

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

      25 N*m

      255 kgf*cm

      18 ft.*lbf

    3. E190152

      Connect the connector.

    4. Attach the 2 clamps.

  3. CONNECT SUCTION HOSE SUB-ASSEMBLY

    1. Remove the attached vinyl tape from the hose and compressor.

    2. for HFC-134a (R134a):

      Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the cooler compressor assembly.

      Compressor oil

      ND-OIL 8 or equivalent

    3. for HFO-1234yf (R1234yf):

      Apply sufficient compressor oil (ND-OIL 12) to a new O-ring and the fitting surface of the cooler compressor assembly.

      Compressor oil

      ND-OIL 12 or equivalent

    4. Install the O-ring to the suction hose sub-assembly.

    5. E190151

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

      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. for HFC-134a (R134a):

      Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the cooler compressor assembly.

      Compressor oil

      ND-OIL 8 or equivalent

    3. for HFO-1234yf (R1234yf):

      Apply sufficient compressor oil (ND-OIL 12) to a new O-ring and the fitting surface of the cooler compressor assembly.

      Compressor oil

      ND-OIL 12 or equivalent

    4. Install the O-ring to the discharge hose sub-assembly.

    5. E189994

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

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

  5. INSTALL V-RIBBED BELT

    1. for 1ZR-FAE:

      Install the V-ribbed belt (Click here).

    2. for 2ZR-FAE:

      Install the V-ribbed belt (Click here).

  6. ADJUST V-RIBBED BELT

    1. for 1ZR-FAE:

      Adjust the V-ribbed belt (Click here).

    2. for 2ZR-FAE:

      Adjust the V-ribbed belt (Click here).

  7. INSPECT V-RIBBED BELT

    1. for 1ZR-FAE:

      Inspect the V-ribbed belt (Click here).

    2. for 2ZR-FAE:

      Inspect the V-ribbed belt (Click here).

  8. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  9. INSTALL REAR ENGINE UNDER COVER RH

    Click here

  10. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  11. INSTALL FRONT LOWER BUMPER ABSORBER

    Click here

  12. CHARGE REFRIGERANT

    1. for HFC-134a(R134a):

      (Click here)

    2. for HFO-1234yf(R1234yf):

      (Click here)

  13. WARM UP ENGINE

    1. for HFC-134a(R134a):

      (Click here)

    2. for HFO-1234yf(R1234yf):

      (Click here)

  14. CHECK FOR REFRIGERANT GAS LEAK

    1. for HFC-134a(R134a):

      (Click here)

    2. for HFO-1234yf(R1234yf):

      (Click here)

  15. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  16. INSTALL NO. 2 CYLINDER HEAD COVER

    Click here