Compressor HVAC: Service and Repair
Compressor And Pulley (For 2GR-FSE 2WD):
Compressor And Pulley (For 2GR-FSE 2WD):
COMPRESSOR AND PULLEY (for 2GR-FSE 2WD)
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 FAN AND GENERATOR V BELT
8. REMOVE ENGINE UNDER COVER
9. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE
a. Remove the bolt and disconnect the cooler refrigerant 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.
10. 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.
11. REMOVE COMPRESSOR ASSEMBLY
a. Disconnect the magnetic clutch connector.
b. Remove the 3 bolts and nut.
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.
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 3 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.
3. 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)
4. 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)
5. INSTALL ENGINE UNDER COVER
6. INSTALL FAN AND GENERATOR V BELT
7. INSTALL NO. 1 AIR CLEANER INLET
8. INSTALL ENGINE ROOM LH SIDE COVER
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHARGE REFRIGERANT
11. INSTALL COOL AIR INTAKE DUCT SEAL
12. WARM UP ENGINE
13. CHECK FOR LEAKAGE OF REFRIGERANT
14. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.