Installation
HEATING / AIR CONDITIONING: COMPRESSOR (for 2GR-FE): 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 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 when replacing the 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 pulley facing down, rotate the hub 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 hub 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 AND MAGNETIC CLUTCH
(a) Install the compressor and magnetic clutch and bracket with the 4 bolts.
Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)
NOTICE:
Tighten the bolts in the order shown in the illustration to install the cooler compressor.
3. CONNECT SUCTION HOSE SUB-ASSEMBLY
(a) Remove the vinyl tape from the hose and compressor and magnetic clutch.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring to the suction hose sub-assembly.
(d) Connect the suction hose sub-assembly to the compressor and magnetic clutch with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
(a) Remove the vinyl tape from the hose and compressor and magnetic clutch.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring to the No. 1 cooler refrigerant discharge hose.
(d) Connect the No. 1 cooler refrigerant discharge hose to the compressor and magnetic clutch with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(e) Engage the 2 clamps and connect the 3 connectors.
5. INSTALL V-RIBBED BELT Installation
6. INSTALL FRONT FENDER APRON SEAL RH
7. INSTALL RADIATOR ASSEMBLY
Installation
8. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT Service and Repair
9. WARM UP ENGINE Service and Repair
10. INSPECT FOR REFRIGERANT LEAK Service and Repair