Installation
HEATING / AIR CONDITIONING: COMPRESSOR: INSTALLATION
1. ADJUST COMPRESSOR OIL
(a) When replacing the compressor with a new one:
(1) Remove the drain bolt (washer).
Text in Illustration
(2) Gradually discharge the refrigerant gas from the service valve. Then drain the following amount of oil from the new compressor before installation, so that the amount of oil contained in the new compressor is the same as that in the compressor to be replaced.
HINT
New compressors are filled with a sufficient amount of oil for the whole cycle. Therefore, it is necessary to drain oil from the new compressor as there is residual oil in other parts.
Text in Illustration
Standard:
(The amount of oil inside a new cooler compressor assembly: 100 to 115 cc (6.10 to 7.02) fl.oz)) - (The amount of oil remaining in the removed cooler compressor assembly A + oil remaining in the reserve chamber: 60 cc (3.66 fl.oz)) = (The amount of oil to be removed when replacing the compressor)
NOTICE:
* When A + 60 cc (3.66 fl.oz) exceeds the standard oil volume specified for the cooler compressor assembly by part number, install the compressor without adjusting the oil volume.
Example:
If A = 45 cc (2.75 fl.oz), A + 60 cc (3.66 fl.oz) = 105 cc (6.41 fl.oz). If the standard volume is 100 cc (6.10 fl.oz), install the cooler compressor as is.
* When checking the compressor oil level, follow the A/C system's precautions.
* If the amount of oil remaining in the removed compressor is low, check for an oil leak.
* Use ND-OIL8 or equivalent for compressor oil.
(3) Install the drain bolt (washer).
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
(b) If draining the oil is difficult, drain the oil using the following procedure:
(1) Remove the suction seal cap.
(2) Lightly shake the compressor with the suction port facing down and drain the oil.*1
NOTICE:
Do not allow compressor oil to come into contact with the pulley.
(c) With the DL pulley facing down, rotate the pulley in the direction shown by the arrow 10 times at a rate of approximately once every 2 seconds.*2
CAUTION:
When the pulley is rotated, refrigerant or oil may splash out. Thus, keep your face away from the compressor port.
(d) Rotate the pulley once in the direction shown by the arrow while quickly turning the compressor so that the pulley is facing up.*3
(e) Perform procedure *1 and drain the oil.*4
(f) Drain the oil by repeating the procedures above (*2 to *4) approximately 5 times.
2. INSTALL COOLER COMPRESSOR ASSEMBLY
(a) Using an E8 "TORX" socket, install the cooler compressor with the 2 stud bolts.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(b) Install the 2 bolts and 2 nuts.
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTICE:
Tighten the bolts and nuts in the order shown in the illustration.
3. INSTALL SUCTION HOSE SUB-ASSEMBLY
(a) Remove the vinyl tape from the hose and compressor.
(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 suction sub-assembly.
(d) Install the suction hose sub-assembly to the cooler compressor with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
4. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
(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 No. 1 cooler refrigerant discharge hose.
(d) Install the No. 1 cooler refrigerant discharge hose to the cooler compressor with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(e) Connect the 2 connectors and attach the 3 clamps.
5. INSTALL REAR ENGINE UNDER COVER RH Installation
6. INSTALL NO. 1 ENGINE UNDER COVER Installation
7. INSTALL CENTER ENGINE UNDER COVER Installation
8. INSTALL GENERATOR ASSEMBLY Installation
9. INSTALL FAN AND GENERATOR V BELT Installation
10. 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.
11. CHARGE REFRIGERANT Service and Repair
12. WARM UP ENGINE Service and Repair
13. CHECK FOR REFRIGERANT LEAK Testing and Inspection