COMPRESSOR AND PULLEY (for 2AD-FHV) > INSTALLATION

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1. ADJUST COMPRESSOR OIL

  1. When replacing the compressor and magnetic 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 magnetic clutch before installation.

    Standard:
    (Oil capacity inside the new compressor and magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.) ) -(Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing)

    NOTICE:
    1. When checking the compressor oil level, observe the precautions on the cooler removal/installation.
    2. If a new compressor and magnetic clutch 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.
    3. If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
    4. Be sure to use ND-OIL 8 or equivalent for compressor oil.


2. INSTALL COOLER COMPRESSOR ASSEMBLY


    E126953E02

  1. w/o Stud Bolt:
    Install the cooler compressor with the 4 bolts.

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

    NOTICE:
    Tighten the bolts in the order shown in the illustration to install the cooler compressor.

  1. w/ Stud Bolt:
    Install the cooler compressor with the 3 bolts and nut.

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

    NOTICE:
    Tighten the bolts in the order shown in the illustration to install the cooler compressor.

  1. Connect the connector.



3. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    H102038

  1. Remove the attached vinyl tape from the hose.

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

    Compressor oil:
    ND-OIL 8 or equivalent

  1. Install the O-ring on the cooler refrigerant discharge hose.

  1. Install the cooler refrigerant discharge hose on the cooler compressor with the bolt.

    Torque:
    9.8 N*m{ 100 kgf*cm , 7 ft.*lbf }


4. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE


    H102041

  1. Remove the attached vinyl tape from the hose.

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

    Compressor oil:
    ND-OIL 8 or equivalent

  1. Install the O-ring on the cooler refrigerant suction hose.

  1. Install the cooler refrigerant suction hose on the cooler compressor with the bolt.

    Torque:
    9.8 N*m{ 100 kgf*cm , 7 ft.*lbf }


5. INSTALL FAN & GENERATOR V BELT


  1. Using SST and a 22 mm wrench, rotate the tensioner pulley counterclockwise, and then install the fan and generator V belt.

    SST
    09216-42010  

    CAUTION:
    1. Be careful as the wrench only fits loosely on the belt tensioner tool set point. The wrench may come off the set point and cause injuries.
    2. Be careful that your hands do not become jammed between parts such as the belt, pulleys, etc.

    NOTICE:
    1. Make sure that the belt is set properly on each pulley.
    2. Make sure SST is installed as shown in the illustration. If not, SST and/or the belt may not be able to be removed.


    A202342E01



6. INSTALL NO. 1 ENGINE UNDER COVER

  1. Install the engine under cover with the 6 bolts and 10 clips.



7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


8. CHARGE REFRIGERANT

  1. Perform vacuum purging using a vacuum pump.



  1. Charge refrigerant HFC-134a (R134a).

    Standard:
    430 +-30 g (15.2 +-1.1 oz.)
    SST
    09985-20010   (09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070)


    I037365E02

    NOTICE:
    1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
    2. 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.


9. WARM UP ENGINE

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

    NOTICE:
    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.


10. CHECK FOR LEAKAGE OF REFRIGERANT

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

  1. Perform the operation under these conditions:

    1. Stop the engine.
    2. Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
    3. Repeat the test 2 or 3 times.
    4. Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)


    I042222E12

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

  1. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

  1. Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.