Installation
HEATING / AIR CONDITIONING: COMPRESSOR (for 2AR-FE): INSTALLATION
1. ADJUST COMPRESSOR OIL LEVEL
(a) When replacing the compressor with a new one:
(1) Remove the drain bolt (washer).
Text in Illustration
(2) Gradually discharge the inert 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 air conditioning system. Therefore, it is necessary to drain oil from the new compressor to compensate for oil remaining in the condenser and cooling unit.
Text in Illustration
Standard:
(The amount of oil inside a new compressor: 100 (+15) cc (6.10 (+0.92) fl.oz)) - (The amount of oil remaining in the old compressor A + oil remaining in the reserve chamber: 60 cc (3.66 fl.oz)) = (The amount of oil to be removed from the new compressor)
NOTICE:
* When A + 60 cc (3.66 fl.oz) exceeds the standard oil fill volume specified for the compressor 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 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 oil leaks.
* 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 COMPRESSOR ASSEMBLY WITH PULLEY
(a) Using an E8 "TORX" socket, temporarily install the compressor assembly with pulley with the 2 stud bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
HINT
Tighten the stud bolts in the order shown in the illustration.
(b) Install the compressor assembly with pulley with the 2 bolts and 2 nuts.
Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)
HINT
Tighten the bolts and nuts in the order shown in the illustration to install the compressor.
3. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
(a) Remove the attached vinyl tape from the hose.
(b) Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and pulley.
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 onto the compressor and pulley with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
4. INSTALL SUCTION HOSE SUB-ASSEMBLY (for TMMK Made)
(a) Remove the attached vinyl tape from the hose.
(b) Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and pulley.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring onto the suction hose sub-assembly.
(d) Install the suction hose sub-assembly onto the compressor assembly with pulley with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(e) Connect the 2 connectors.
(f) Install the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
5. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE (for SIA Made)
(a) Remove the attached vinyl tape from the hose.
(b) Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and pulley.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring onto the No. 1 cooler refrigerant suction hose.
(d) Install the No. 1 cooler refrigerant suction hose onto the compressor assembly with pulley with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(e) Connect the 2 connectors.
(f) Install the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
6. INSTALL V-RIBBED BELT Installation
7. INSTALL FRONT FENDER APRON SEAL RH
8. INSTALL RADIATOR ASSEMBLY
Installation
9. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT Service and Repair
10. WARM UP ENGINE Service and Repair
11. INSPECT FOR REFRIGERANT LEAK Service and Repair