GSIC - Global Service Information Center

# COMPRESSOR AND PULLEY (for TR Series Engine) > INSTALLATION

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1. ADJUST COMPRESSOR OIL

1. 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: 80 + 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.

2. INSTALL COOLER COMPRESSOR ASSEMBLY

1. 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 }

1. Connect the connector.

3. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

1. Remove the vinyl tape attached to the hose.

1. Sufficiently apply compressor oil 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.

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

4. INSTALL SUCTION HOSE SUB-ASSEMBLY

1. Remove the vinyl tape attached to the hose.

1. Sufficiently apply compressor oil 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.

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

5. INSTALL DRIVE BELT

1. Install the drive belt to the pulleys except the drive belt tensioner pulley.

1. Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and then install the drive belt to the tensioner pulley.

   NOTICE:
   1. The backside of the drive belt should face the tensioner pulley.
   2. Check that the drive belt is properly set to each pulley.

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

6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

7. 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.

8. CHARGE REFRIGERANT

1. Perform vacuum purging using a vacuum pump.

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

   Standard:
     450 +- 30 g (15.87 +- 1.05 oz.)
   SST
     07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

   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.

9. WARM UP ENGINE

1. 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.

10. 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)

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.