Compressor Pulley: Service and Repair
Compressor And Pulley (For 2GR-FSE 4WD):
Compressor And Pulley (For 2GR-FSE 4WD):
COMPRESSOR AND PULLEY (for 2GR-FSE 4WD)
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTE: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE COOL AIR INTAKE DUCT SEAL
3. REMOVE ENGINE ROOM SIDE COVER LH
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
5. REMOVE NO. 1 AIR CLEANER INLET
6. REMOVE V-BANK COVER
7. REMOVE ENGINE UNDER COVER
8. REMOVE FAN AND GENERATOR V BELT
9. REMOVE OIL FILTER BRACKET
a. Remove the bolt, nut and oil filter bracket.
10. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
a. Detach the 2 clamps, and disconnect the connector and wire harness.
b. Remove the bolt, 2 nuts and oil filter bracket.
HINT: Collect the engine oil in a container.
11. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE
a. Remove the bolt and disconnect the suction hose from the compressor.
b. Remove the O-ring from the cooler refrigerant suction hose.
NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
12. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY
a. Remove the bolt and disconnect the discharge hose from the compressor.
b. Remove the O-ring from the discharge hose.
NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
13. REMOVE COMPRESSOR ASSEMBLY
a. Disconnect the magnetic clutch connector.
b. Remove the 2 bolts, nut and oil filter bracket.
c. Using an E8 "torx" socket, remove the stud bolt and compressor.
INSTALLATION
1. ADJUST COMPRESSOR OIL
a. When replacing the compressor with a new one, after gradually discharging the refrigerant gas from the service valve, drain the following volume of oil from the new compressor before installation.
Standard: (Oil capacity inside a new compressor: 130 + 15 cc (4.6 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed from the new compressor when replacing it.
NOTE:
- When checking the compressor oil level, observe the precautions in the cooler removal/installation.
- If a new compressor is installed without removing some oil remaining in the pipes of the vehicle, the oil amount becomes excessive. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure.
- If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
- Be sure to use ND-OIL 8 for compressor oil.
2. INSTALL COMPRESSOR ASSEMBLY
a. Using an E8 "torx" socket, install the compressor with the stud bolt.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
b. Install the compressor with the 2 bolts and nut.
HINT: Temporarily install the bolts and nut.
3. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
a. Install a new oil filter bracket gasket and the oil filter bracket with the 2 nuts and bolt.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
b. Install the wire harness to connect the connector and attach the 2 clamps.
4. INSTALL OIL FILTER BRACKET
a. Install the oil filter bracket with the bolt and nut.
Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
HINT: Temporarily install the bolt.
5. TIGHTEN COMPRESSOR ASSEMBLY
a. Install the compressor with the bolts and nut.
Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
NOTE: Tighten the bolts in the order given in the illustration to install the compressor.
6. INSTALL DISCHARGE HOSE SUB-ASSEMBLY
a. Remove the attached vinyl tape from the discharge hose.
b. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor.
Compressor oil: ND-OIL 8 or equivalent
c. Install the O-ring on the discharge hose.
d. Install the discharge hose on the compressor with the bolt.
Torque: 9.8 N.m (100 kgf.cm, 7 in.lbf)
7. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE
a. Remove the attached vinyl tape from the suction hose.
b. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor.
Compressor oil: ND-OIL 8 or equivalent
c. Install the O-ring on the suction hose.
d. Install the suction hose on the compressor with the bolt.
Torque: 9.8 N.m (100 kgf.cm, 7 in.lbf)
8. INSTALL ENGINE UNDER COVER
9. INSTALL FAN AND GENERATOR V BELT
10. INSTALL V-BANK COVER
11. INSTALL NO. 1 AIR CLEANER INLET
12. INSTALL ENGINE ROOM SIDE COVER LH
13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
14. CHARGE REFRIGERANT
15. INSTALL COOL AIR INTAKE DUCT SEAL
16. WARM UP ENGINE
17. CHECK FOR LEAKAGE OF REFRIGERANT
18. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.