Compressor And Pulley (For 3Zr-Fae) Installation

When replacing the compressor assembly with pulley with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor assembly with pulley before installation.

Standard:

(Oil capacity inside the new compressor assembly with pulley: 100 + 15 cc (3.38 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor assembly with pulley) = (Oil amount to be removed from the new compressor)

NOTICE:

1. When checking the compressor oil level, follow the A/C system precautions.
   
2. If a new compressor assembly with pulley is installed without removing the 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.
   
3. If the volume of oil remaining in the removed compressor assembly with pulley is small, check for oil leakage.
   
4. Be sure to use ND-OIL 8 or equivalent compressor oil.
   

Install the cooler compressor with the 2 stud bolts.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Install the 2 bolts and 2 nuts.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

NOTICE:

Tighten the bolts in the order shown in the illustration to install the cooler compressor.

Connect the connector.

Remove the vinyl tape from the hose and compressor.

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

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring to the cooler refrigerant suction hose.

Install the cooler refrigerant suction hose to the cooler compressor with the bolt.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Remove the attached vinyl tape from the hose.

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

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring to the cooler refrigerant discharge hose.

Install the cooler refrigerant discharge hose to the cooler compressor with the bolt.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Temporarily install the V-ribbed belt.

Connect the radiator reservoir with the 2 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Connect the No. 1 and No. 2 water by-pass hoses.

Install the radiator support opening cover with the 9 clips.

Install the reinforcement with the 4 bolts.

Torque:

96 N*m{979 kgf*cm, 71 ft.*lbf}

Install the under cover with the 3 clips.

Install the under cover with the 6 screws and 10 clips.

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

Standard:

430 +-30 g (15.2 +-1.1 oz.)

SST

09985-20010(09985-02130,09985-02150,09985-02090,09985-02110,09985-02010,09985-02050,09985-02060,09985-02070)

NOTICE:

1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
   
2. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
   

Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging the refrigerant.

NOTICE:

Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

Perform the operation under these conditions:

1. Stop the engine.
   
2. Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
   
3. Repeat the test 2 or 3 times.
   
4. Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)
   

Using a gas leak detector, check the refrigerant line for leakage.

If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.