COMPRESSOR (for GD Series Engine) INSTALLATION


  1. ADJUST COMPRESSOR OIL

    B007RRY

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

      Standard
      (The amount of oil inside a new cooler compressor: 180 to 195 cc (6.1 to 6.6 fl. oz.)) - (The amount of oil remaining in the removed cooler compressor) = (The amount of oil to be removed when replacing the compressor)

      Note


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

      • If a new cooler compressor is installed without removing some 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 cooler compressor is too small, check for oil leakage.

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

  2. INSTALL COOLER COMPRESSOR ASSEMBLY

    B007SMC

    1. Using an E8 "TORX" socket wrench, install the cooler compressor assembly with the 2 stud bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. B007S9Z

      Temporarily install the 2 bolts.

    3. B007VOYE01

      Temporarily install the 2 nuts.

    4. Tighten the 2 bolts and 2 nuts in the sequence shown in the illustration.

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

    5. Attach the clamp and connect the connector.

  3. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. Remove the attached vinyl tape from the No. 1 cooler refrigerant suction hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. Connect the No. 1 cooler refrigerant suction hose to the cooler compressor with the bolt.

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

  4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


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

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

      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 to the cooler compressor with the bolt.

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

  5. INSTALL GENERATOR ASSEMBLY

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  6. INSTALL V-RIBBED BELT


    1. Set the fan and generator V belt onto each part.

      Tech Tips

      When installing the fan and generator V belt, attach the fan and generator V belt to the No. 1 idler pulley sub-assembly last.

    2. While turning the V-ribbed belt tensioner assembly clockwise, remove the pin.

    3. Check that the fan and generator V belt fits properly in the ribbed grooves.

      Note

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

  7. CHARGE REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      B007T4RE01
      Standard
      Single A/C
      520 to 580g (18.3 to 20.5 oz.)
      Dual A/C
      670 to 730g (23.0 to 25.7 oz.)
      SST
      07110-58060   ( 07117-58090, 07117-78050, 07117-58070, 07117-58060, 07117-58080, 07117-88060, 07117-88070, 07117-88080 )

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor does not work properly without any refrigerant, which causes the compressor to overheat.

      • Approximately 100 g (3.5 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.

      Tech Tips

      Prepare a service can to recharge refrigerant if using the refrigerant gas collected with the freon collection/recycling device because the collective rate of the device is approximately 90%.

  8. WARM UP ENGINE


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

      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.

  9. CHECK FOR REFRIGERANT GAS LEAK


    1. After recharging refrigerant gas, check for leakage of refrigerant gas using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Stop the engine.

      • Secure good ventilation (the gas 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. B007S0PE02

      Using a gas leak detector, check for leakage of the refrigerant line.

    4. B007U25E01

      Bring the gas leak detector close to the drain hose with the detector's power off.

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring the gas leak detector sensor under the drain hose.

      • When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.

        If such reaction is unavoidable, the vehicle must be lifted up.

    5. If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas 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 gas leak detector close to the pressure switch and perform the test.