3UZ-FE COMPRESSOR AND PULLEY > INSTALLATION

for Preparation Click here



1. ADJUST COMPRESSOR OIL

  1. When replacing the compressor and magnetic clutch with a new one, after gradually discharging the refrigerant gas from the service valve, drain the following volume of oil from the new compressor and magnetic clutch before installation.

    Standard:
    (Oil capacity inside a new compressor and magnetic clutch: 130+ 15 cc (4.6 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing the compressor)

    NOTICE:
    1. When checking the compressor oil level, observe the precautions in the cooler removal/installation.
    1. If a new compressor and magnetic clutch are installed without removing some oil remaining in the pipes of the vehicle, the oil amount becomes excessive. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure.
    1. If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
    1. Be sure to use ND-OIL 8 for compressor oil.



2. INSTALL COMPRESSOR ASSEMBLY


    E102696

  1. Hang the compressor bracket onto the fan bracket and temporarily install the compressor with the bolt.



    E102697E01

  1. Install the compressor with the 3 bolts, nut and bracket.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf } for bolt
    29.4 N*m{ 300 kgf*cm , 22 ft.*lbf } for nut

    NOTICE:
    Tighten the bolts in the order shown in the illustration to install the compressor.



3. INSTALL OIL FILTER

  1. Install the oil filter.



4. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (w/ Plug Thermostat)


    E110228E01

  1. Remove the vinyl tape attached to the hose.

  1. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor.

    Compressor oil:
    ND-OIL 8 or equivalent

  1. Install the O-ring on the discharge hose.

  1. Install the discharge hose on the compressor with the bolt.

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



5. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE


E102693

  1. Remove the vinyl tape attached to the hose.

  1. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor.

    Compressor oil:
    ND-OIL 8 or equivalent

  1. Install the O-ring on the suction hose.

  1. Install the suction hose on the compressor with the bolt.

    Torque:
    9.8 N*m{ 100 kgf*cm , 7 in.*lbf }



6. INSTALL ENGINE UNDER COVER


B107493

  1. Install the under cover with the 3 clips and 10 screws.



7. INSTALL V-RIBBED BELT


    A107652E02

  1. Set the V-belt to everything except the No. 2 idler pulley, as shown in the illustration.

  1. Loosen the V-belt by turning the belt tensioner counterclockwise.

  1. Then set the V-belt to the idler pulley.



    A052038

  1. After a new belt has been installed, check that the mark is within the A range shown in the illustration.



8. INSTALL V-BANK COVER SUB-ASSEMBLY

  1. Install the V-bank cover with the 2 nuts.

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

    NOTICE:
    Make sure that the wire harness does not get caught between parts.



9. INSTALL NO. 1 AIR CLEANER INLET

  1. Install the air cleaner inlet and bolt.

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



10. INSTALL ENGINE ROOM SIDE COVER LH


    B107979E02

  1. Install the side cover with the 3 clips.



11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


12. CHARGE REFRIGERANT

  1. Perform vacuum purging using a vacuum pump.



  1. Charge refrigerant HFC-134a (R134a).

    Standard:
    450 +- 50 g (15.87 +- 1.76 oz.)

    SST
    07110-58060   (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)


    I037365E02

    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 measuring its quantity, and not with the sight glass.



13. INSTALL COOL AIR INTAKE DUCT SEAL


    A110865E01

  1. Install the intake duct seal with the 7 clips.



14. WARM UP ENGINE

  1. 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.



15. CHECK FOR LEAKAGE OF REFRIGERANT

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

  1. Perform the operation under these conditions:

    1. Stop the engine.
    1. Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
    1. Repeat the test 2 or 3 times.
    1. 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)



    I042222E02

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

  1. 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.

  1. 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.



16. PERFORM INITIALIZATION

  1. Perform initialization (Click here).

    NOTICE:
    Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.