Installation

AIR CONDITIONING: COMPRESSOR (for 2WD): INSTALLATION

1. ADJUST COMPRESSOR OIL

(a) 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:
* When checking the compressor oil level, observe the A/C system's precautions.
* 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.
* 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 or equivalent for compressor oil.

2. INSTALL COOLER COMPRESSOR ASSEMBLY

(a) Install the cooler compressor with the 2 stud bolts

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Install the 2 bolts and 2 nuts.

Torque : 24.5 Nm (250 kgf-cm, 18 ft-lbf)

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

(c) Connect the connector.

3. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

(a) Remove the attached vinyl tape from the hose.

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

Compressor oil:

ND-OIL 8 or equivalent

(c) Install the O-ring to the cooler refrigerant suction hose.

(d) Install the cooler refrigerant suction hose to the cooler compressor with the bolt.

Torque : 9.8 Nm (100 kgf-cm, 7 ft-lbf)

5. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1) Installation

6. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

7. INSTALL POWER STEERING LINK ASSEMBLY

(a) w/ VGRS:

Install the power steering link Installation.

(b) w/o VGRS:

Install the power steering link Installation.

8. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

(a) w/ VGRS:

Install the No. 2 steering intermediate shaft Installation.

(b) w/o VGRS:

Install the No. 2 steering intermediate shaft Installation.

9. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

(a) w/ VGRS:

Install the steering sliding with shaft yoke Installation.

(b) w/o VGRS:

Install the steering sliding with shaft yoke Installation.

10. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH Installation

11. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH Installation

12. INSTALL FRONT STABILIZER BAR Installation

13. INSTALL REAR ENGINE UNDER COVER RH

14. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY Installation

15. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Install the front exhaust pipe Installation.

16. INSTALL ENGINE ROOM ECU OUTLET DUCT Installation

17. INSTALL AIR CLEANER ASSEMBLY RH Installation

18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY RH

19. INSTALL AIR CLEANER ASSEMBLY LH Installation

20. INSTALL AIR CLEANER CAP SUB-ASSEMBLY LH

21. INSTALL FAN & GENERATOR V BELT Installation

22. INSTALL INTAKE AIR CONNECTOR PIPE Installation

23. INSTALL RADIATOR RESERVOIR ASSEMBLY Installation

24. INSTALL NO. 1 AIR CLEANER INLET Installation

25. INSTALL FRONT SUSPENSION CROSSMEMBER LOWER Installation

26. INSTALL REAR FRAME SIDE RAIL

(a) Install the frame rail with the 6 bolts and 4 nuts.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

27. INSTALL RADIATOR SUPPORT OPENING COVER Installation

28. INSTALL FRONT BUMPER COVER

(a) Install the front bumper cover Installation.

29. INSPECT FOR EXHAUST GAS LEAK

30. INSTALL FRONT WHEEL

31. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

32. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

(a) Check and adjust the front wheel alignment Front Wheel Alignment.

33. CHECK SHIFT LEVER POSITION Installation

34. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER Installation

35. INSTALL NO. 2 ENGINE UNDER COVER Installation

36. INSTALL NO. 1 ENGINE UNDER COVER Service and Repair

37. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

38. INSTALL ENGINE ROOM SIDE COVER RH Installation

39. INSTALL ENGINE ROOM SIDE COVER LH Installation

40. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY Installation

41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

42. INSTALL COWL TOP VENTILATOR LOUVER RH Installation

43. ADD COMPRESSOR OIL Service and Repair

44. CHARGE REFRIGERANT Service and Repair

45. WARM UP ENGINE Service and Repair

46. CHECK FOR LEAKAGE OF REFRIGERANT Service and Repair