Compressor And Pulley (For 1Kd-Ftv) Installation

When replacing the compressor with a new one after gradually releasing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor before installation.

Standard:

(Oil capacity inside new compressor: 180 + 15 cc (2.7 + 0.5 fl. oz.)) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed when replacing)

NOTICE:

1. When checking the compressor oil level, follow the A/C system's precautions.
   
2. Since compressor oil remains in the pipes of the vehicle, if a new compressor is installed without removing some oil inside, the oil amount becomes excessive. Excessive oil prevents heat exchange in the refrigerant cycle and causes refrigerant failure.
   
3. If the remaining oil in the removed compressor is too low, check for oil leakage.
   
4. Be sure to use ND-OIL 8 for compressor oil.
   

Install the compressor with the 4 bolts and tighten the bolts in the order shown in the illustration.

Torque:

24.5 N*m{250 kgf*cm, 18 ft.*lbf}

Connect the connector.

Remove the vinyl tape attached to the hose.

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

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring on the discharge hose.

Connect the discharge hose with the bolt.

Torque:

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

Remove the vinyl tape attached to the hose.

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

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring on the suction hose.

Connect the suction hose with the bolt.

Torque:

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

Rotate the tensioner pulley clockwise, and then install the V belt.

NOTICE:

Make sure that the V belt is set properly at each pulley.

Make sure that the indicator mark of the tensioner is within range A, as shown in the illustration.

Connect the air cleaner hose.

Install the cleaner with the 2 bolts.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Connect the connector to the MAF meter.

Tighten the hose clamp.

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

Standard:

750 +-30 g (26.45 +-1.05 oz.)

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.
   

1. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.
   

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

After recharging the refrigerant gas, prepare the vehicle for a refrigerant gas leakage check by making sure the following conditions are met.

1. The ignition switch is OFF.
   

2. The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive gases, If volatile gases are unavoidable, the vehicle must be lifted up.
   

3. Some refrigerant is remaining in the refrigerant system.
   

4. The compressor is OFF and its pressure is approximately 392 to 588 kPa (4 to 6 kgf/cm2).
   

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.