COMPRESSOR AND PULLEY (for 2KD-FTV) > INSTALLATION

for Preparation Click here



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


I043253E02

  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


I043252E01

  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


I043251E03

  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


G035153E01

  1. Use the pulley set bolt of the tensioner to rotate the tensioner pulley clockwise, and then install the V belt.

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



    A114802E01

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



6. INSTALL AIR CLEANER ASSEMBLY


    A110353

  1. Connect the air cleaner hose.

  1. Install the air cleaner with the 2 bolts.

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

  1. Tighten the clamp.

  1. Install the clamp and connect the IAT connector.

  1. Connect the ventilation hose.

  1. Slide the clamp to the connection of the hose.



7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


8. 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.



9. 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)


    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 quantity, and not with the sight glass.



10. 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.



11. 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.