COMPRESSOR(for 8GR-FKS) INSTALLATION

CAUTION / NOTICE / HINT

Note

for HFO-1234yf (R1234yf):


  • Always use ND-OIL 12 as the compressor oil.

  • The oil used for HFC-134a (R134a) systems (ND-OIL 8) does not work well in HFO-1234yf (R1234yf) systems. If the oil used for HFC-134a (R134a) systems (ND-OIL 8) is used in an HFO-1234yf (R1234yf) system, it will result in degradation of the refrigerant and deterioration of resin parts.

for HFC-134a (R134a):


  • The recommended compressor oil listed on the compressor assembly and on the engine hood may differ. Make sure to use the compressor oil listed on the engine hood.

  • If ND-OIL 12 is mixed with the ND-OIL 8 in the system, the performance of the air conditioning system will not be affected.

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

PROCEDURE


  1. ADJUST COMPRESSOR OIL


    1. When replacing the compressor assembly with pulley with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil before installation.

      Note


      • If a new compressor assembly with pulley is installed without removing the same amount of compressor oil as is remaining in the pipes, the amount of compressor oil will be excessive. This prevents heat exchange in the refrigerant cycle and will cause the air conditioning system to malfunction.

      • A certain amount of compressor oil remains in the compressor assembly with pulley during circulation and the compressor may be damaged if the amount of compressor oil is more/less than this amount. Therefore, make sure to adjust the amount of compressor oil correctly.

      • If the amount of compressor oil remaining in the removed compressor assembly with pulley is excessively low, check for compressor oil leaks.

      • for HFC-134a(R134a): Make sure to use ND-OIL 8 or equivalent compressor oil.

      • for HFO-1234yf(R1234yf): Make sure to use ND-OIL 12 or equivalent compressor oil.

    2. B006AJU

      Remove the drain bolt (seal washer) from the removed compressor assembly with pulley.

    3. Drain the compressor oil from the oil port of the removed compressor assembly with pulley as shown in the illustration.

      Note

      Make sure to drain the compressor oil from the oil port.

      B006EE8C01
      *a Oil Port *b Turn Clockwise
    4. B006AJU

      Remove the drain bolt (seal washer) from the new compressor assembly with pulley.

      Tech Tips

      The drain bolt (seal washer) can be reused.

    5. Drain the following amount of compressor oil from the oil port of the new compressor assembly with pulley as shown in the illustration.

      Standard
      (The amount of oil in a new compressor assembly with pulley: 100 to 115 cc (3.38 to 3.89 fl.oz)) - (The amount of oil in the removed compressor assembly with pulley) = The amount of oil to be removed from the new compressor assembly with pulley.

      Note


      • Make sure to drain the compressor oil from the oil port.

      • Make sure to add the compressor oil from the oil port, not from the discharge or intake port.

      • If a tool is used to add compressor oil to the new compressor assembly with pulley, make sure that it is free of foreign matter.

      • If the compressor is damaged by a vehicle collision, etc., compressor oil is spilled and the compressor oil cannot be managed, replace the compressor with a supply part as follows. If the cooler condenser assembly is also replaced, do not add the specified amount of compressor oil for cooler condenser assembly replacement (40 cc (1.35 fl.oz)).

        w/o Rear Cooler
        Install it without changing the amount of compressor oil from the packaged condition.
        w/ Rear Cooler
        Before installing, remove 30 cc (1.01 fl.oz) of compressor oil from the packaged condition.
      B006EE8C01
      *a Oil Port *b Turn Clockwise

    6. Install the drain bolt (seal washer) to the new compressor assembly with pulley.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Make sure that there is no damage or foreign matter on the seal washer edge.

  2. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY


    1. B006FDW

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. B006E7CC03
      B006AHR Bolt
      B006EC9 Nut

      Install the compressor assembly with pulley with the 2 nuts and 2 bolts.

      Note

      Tighten the 2 nuts and 2 bolts in the order shown in the illustration.

      Torque:
      Nut, Bolt
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }
    3. B0069R9

      Install the wiring harness clamp bracket with the bolt.

      Torque:
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }
    4. B006A17

      Connect the connector.

  3. INSTALL SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the suction hose sub-assembly and connecting part of the compressor assembly with pulley and connecting part of the air conditioning tube and accessory assembly.

    2. Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the compressor assembly with pulley and fitting surface of the air conditioning tube and accessory assembly

      Compressor Oil
      Refrigerant Compressor Oil
      HFC-134a (R134a) ND-OIL 8 or equivalent
      HFO-1234yf (R1234yf) ND-OIL 12 or equivalent

    3. Install the 2 new O-rings to the suction hose sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. B006CBKC01
      B006AHR Bolt
      B006EC9 Nut

      Install the suction hose sub-assembly with the bolt and nut.

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

      Note


      • Do not apply excessive force to the suction hose sub-assembly.

      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

  4. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the discharge hose sub-assembly and connecting part of the compressor assembly with pulley.

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

      Compressor Oil
      Refrigerant Compressor Oil
      HFC-134a (R134a) ND-OIL 8 or equivalent
      HFO-1234yf (R1234yf) ND-OIL 12 or equivalent

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

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. B006BC9

      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 }

      Note


      • Do not apply excessive force to the discharge hose sub-assembly.

      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

    5. B006BGG

      Attach the clamp.

    6. B006ENY

      Connect the connector.

  5. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH


    1. B006GYK

      Install the radiator support to crossmember brace sub-assembly LH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  6. INSTALL FAN AND GENERATOR V BELT

    Click here

  7. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  8. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  9. WARM UP ENGINE


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  10. INSPECT FOR REFRIGERANT LEAK


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  11. INSTALL LOWER RADIATOR AIR DEFLECTOR

    Click here

  12. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  13. INSTALL RADIATOR COVER PLATE

    Click here

  14. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here