Installation
AIR CONDITIONING: COMPRESSOR (for 2AR-FE): INSTALLATION
1. ADJUST COMPRESSOR OIL
(a) When replacing the compressor with a new one:
(1) Remove the drain bolt (washer).
(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 it is the same as that in the compressor to be replaced.
HINT
New compressors are filled with sufficient oil for the whole cycle. Therefore, it is necessary to drain residual oil from the condenser and cooling unit.
Standard:
(The amount of oil inside a new cooler compressor assembly: 100 (+15) cc (6.10 (+0.92) 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 fill 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, observe the precautions for cooler removal/ installation.
* If the amount of oil remaining in the removed compressor is too 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 the pulley to come into contact with the compressor oil.
(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:
If the pulley is rotated, refrigerant or oil might 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 the pulley is up (*3).
(e) Proceed with the above procedure (*1) and drain the oil (*4).
(f) Drain the oil by repeating the procedures above approximately 5 times (from (*2) to (*4)).
2. INSTALL COOLER COMPRESSOR ASSEMBLY
(a) Install the cooler compressor with the 2 stud bolts.
Torque : 9.8 Nm (100 kgf-cm, 7 ft-lbf)
(b) Install the 2 bolts and 2 nuts.
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTICE:
Tighten the bolts in the order shown in the illustration to install the cooler compressor.
3. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE
(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 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)
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 cooler refrigerant discharge hose.
(d) Install the cooler refrigerant discharge hose to the cooler compressor with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 7 ft-lbf)
(e) Connect the 2 connectors and attach the 2 clamps.
5. INSTALL FAN & GENERATOR V BELT Installation
6. INSTALL RADIATOR RESERVOIR ASSEMBLY Installation
7. INSTALL RADIATOR SUPPORT OPENING COVER Installation
8. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH Installation
9. INSTALL REAR ENGINE UNDER COVER RH Installation
10. INSTALL NO. 1 ENGINE UNDER COVER Installation
11. INSTALL FRONT WHEEL RH
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHARGE REFRIGERANT Service and Repair
14. WARM UP ENGINE Service and Repair
15. INSPECT FOR REFRIGERANT LEAK Service and Repair