Almera Tino V10 (2003 year). Manual — part 42
REFRIGERANT LINES
ATC-129
C
D
E
F
G
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K
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A
B
ATC
*1
ATC-20, "LUBRICANT RETURN
OPERATION"
*2
ATC-143, "Checking for Refrigerant
Leaks"
*3
ATC-143, "Checking for Refrigerant
Leaks"
*4
ATC-84, "PERFORMANCE TEST
DIAGNOSES"
SHA383F
ATC-130
REFRIGERANT LINES
Components
EJS0031B
QG ENGINE MODELS
Refer to
ATC-5, "Precautions for Refrigerant Connection"
.
RHA270I
REFRIGERANT LINES
ATC-131
C
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A
B
ATC
YD22DDT ENGINE MODELS
RJIA2358E
ATC-132
REFRIGERANT LINES
YD22DDTI ENGINE MODELS
RJIA2341E
REFRIGERANT LINES
ATC-133
C
D
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A
B
ATC
Compressor
EJS0031C
REMOVAL
With QG Engine
With YD Engine
1.
Use refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2.
Disconnect the compressor connector.
3.
Remove the engine under cover (right side).
4.
Remove the compressor-alternator belt.
Refer to
EM-15, "Removal and Installation"
(QG engine),
EM-118, "Removal and Installation"
(YD
engine).
RJIA0833E
RJIA0834E
ATC-134
REFRIGERANT LINES
5.
Remove the mounting nuts (bolts) from the high-pressure flexi-
ble hose and low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
6.
Remove the mounting bolts from compressor.
7.
Remove the compressor from the lower side of the vehicle.
INSTALLATION
CAUTION:
●
Replace the O-ring of the low-pressure flexible hose and
high-pressure flexible hose with a new one, then apply
compressor oil to it when installing it.
●
When pouring refrigerant, check for leaks.
RJIA1729E
RJIA1730E
RJIA0837E
Compressor mounting bolt (QG engine)
Tightening torque
: 50 - 60 N·m (5.1 - 6.9 kg-m, 37 - 49
ft-lb)
Compressor mounting bolt (YD engine)
Tightening torque
: 60 - 69 N·m (6.1 - 7.1 kg-m, 45 - 51
ft-lb)
Compressor bracket mounting bolt (QG engine)
Tightening torque
: 34 - 46 N·m (3.4 - 4.7 kg-m, 25 - 33
ft-lb)
Compressor bracket mounting bolt (YD engine)
Tightening torque
: 57 - 65 N·m (5.8 - 6.7 kg-m, 42 - 48
ft-lb)
Nut (bolt) mounting the high-pressure flexible hose
Tightening torque
: 7.8 - 19.6 N·m (0.8 - 2.0 kg-m, 69 -
173 in-lb)
RJIA0838E
REFRIGERANT LINES
ATC-135
C
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A
B
ATC
Compressor Clutch
EJS0031D
REMOVAL
Overhaul
1.
When removing center bolt, hold clutch disc with wrench.
2.
Remove the clutch disc using the clutch disc puller.
3.
Remove the snap ring using external snap ring pliers.
Nut (bolt) mounting the low-pressure flexible hose
Tightening torque
: 7.8 - 19.6 N·m (0.8 - 2.0 kg-m, 69 -
173 in-lb)
RHA136EB
RHA399F
RHA124F
RHA138E
ATC-136
REFRIGERANT LINES
4.
Position the center pulley puller on the end of the drive shaft,
and remove the pulley assembly using any commercially avail-
able pulley puller.
To prevent the pulley groove from being deformed, the puller
claws should be positioned into the edge of the pulley assembly.
5.
Remove the field coil harness clip using a pair of pliers.
6.
Remove the snap ring using external snap ring pliers.
Inspection
Clutch disc
If the contact surface shows signs of damage due to excessive heat,
replace clutch disc and pulley.
Pulley
Check the appearance of the pulley assembly. If the contact surface
of pulley sows signs of excessive grooving, replace clutch disc and
pulley. The contact surfaces of the pulley assembly should be
cleaned with a suitable solvent before reinstallation.
Coil
Check coil for loose connection or cracked insulation.
INSTALLATION
1.
Install the field coil.
RHA139E
RHA125F
RHA145E
RHA126F
REFRIGERANT LINES
ATC-137
C
D
E
F
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A
B
ATC
Be sure to align the coil
′
s pin with the hole in the compressor
′
s
front head.
2.
Install the field coil harness clip using a screwdriver.
3.
Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.
4.
Install the clutch disc on the drive shaft, together with the original
shim(s). Press the clutch disc down by hand.
5.
Using the holder to prevent clutch disc rotation.
After tightening the bolt, check that the pulley rotates smoothly.
6.
Check clearance around the entire periphery of clutch disc.
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
RHA142E
RHA143EA
RHA127F
Tightening torque
: 14 N·m (1.4 kg-m, 10 ft-lb)
RHA086E
Disc to pulley clear-
ance
: 0.3 - 0.6 mm (0.012 - 0.024 in)
RHA087E
ATC-138
REFRIGERANT LINES
Break-In Operation
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engag-
ing and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.
Low-pressure Flexible Hose
EJS0031E
REMOVAL
1.
Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2.
Remove the clip from the low-pressure flexible hose.
3.
Remove the mounting bolts from the low-pressure flexible hose.
4.
Remove the low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
CAUTION:
●
Replace the O-ring of the low-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
●
When pouring refrigerant, check for leaks.
High-pressure Flexible Hose
EJS0031F
REMOVAL
1.
Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2.
Remove the clip from high-pressure flexible hose.
3.
Remove the mounting bolt and nut from the high-pressure flexi-
ble hose, then remove it.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
RJIA1731E
RJIA0185E
Low-pressure flexible hose and bolts mounting the high-pressure pipe (evapo-
rator side)
Tightening torque
:2.9 - 5.9 N·m (0.29 - 0.6 kg-m, 26 - 52 in-lb)
Nut (Bolt) mounting the low-pressure flexible hose (compressor side)
Tightening torque
:7.8 - 19.6 N·m (0.8 - 2.0 kg-m, 70 - 173 in-lb)
RJIA1735E
REFRIGERANT LINES
ATC-139
C
D
E
F
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A
B
ATC
INSTALLATION
CAUTION:
●
Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
●
When pouring refrigerant, check for leaks.
High-pressure Pipe
EJS0031G
REMOVAL
1.
Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2.
Remove the low-pressure flexible hose. Refer to
.
3.
Remove the high-pressure pipe from the clip.
4.
Remove the mounting bolt from the high-pressure pipe.
5.
Remove the high-pressure pipe.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
CAUTION:
●
Replace the O-ring of the high-pressure pipe and low-pressure flexible hose with a new one, then
apply compressor oil to it when installing it.
●
When pouring refrigerant, check for leaks.
Bolt and nut mounting the high-pressure flexible hose
Tightening torque
:7.8 - 19.6 N·m (0.8 - 2.0 kg-m, 70 - 173 in-lb)
RJIA1720E
RJIA0030E
Bolts mounting the high-pressure pipe (condenser side, evaporator side)
Tightening torque
:2.9 - 5.9 N·m (0.29 - 0.6 kg-m, 26 - 52 in-lb)
ATC-140
REFRIGERANT LINES
Refrigerant Pressure Sensor
EJS0031H
REMOVAL AND INSTALLATION
1.
Use refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2.
Remove liquid tank.
3.
Using a vice, secure liquid tank, and remove refrigerant pres-
sure sensor.
CAUTION:
●
When working, be careful not to damage the condenser
fins.
●
Apply compressor oil to the O-ring of the refrigerant
pressure sensor when installing it.
Dual-pressure Switch
EJS0031I
REMOVAL AND INSTALLATION
YD22DDT Engine Models
1.
Use refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2.
Remove liquid tank.
3.
Using a vice, secure liquid tank, and remove refrigerant pres-
sure sensor.
CAUTION:
●
When working, be careful not to damage the condenser
fins.
●
Apply compressor oil to the O-ring of the refrigerant
pressure sensor when installing it.
YD22DDTi Engine Models
1.
Use refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2.
Remove condenser. Refer to
.
3.
Remove dual-pressure switch from condenser.
CAUTION:
●
When working, be careful not to damage the condenser
fins.
●
Apply compressor oil to the O-ring of the refrigerant
pressure sensor when installing it.
Tightening torque
:9.8 - 11.7 N·m (1.0 - 1.2kg-m, 87 -
104 in-lb)
RJIA0698E
Tightening torque
:9.8 - 11.7 N·m (1.0 - 1.2kg-m, 87 -
104 in-lb)
RJIA0699E
Tightening torque
:9.8 - 11.7 N·m (1.0 - 1.2kg-m, 87 -
104 in-lb)
RJIA2343E
REFRIGERANT LINES
ATC-141
C
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ATC
Condenser Assembly
EJS0031J
REMOVAL
1.
Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2.
Disconnect the high-pressure flexible hose and the high-pres-
sure pipe from the condenser.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
3.
Remove the battery and battery tray.
4.
Remove the front grille and radiator mounting bracket.
5.
Remove the mounting nuts from the condenser upper bracket.
6.
Remove the radiator from the lower mount, move it to the engine side, then remove the condenser
between the radiator and the radiator core support.
CAUTION:
Be careful not to damage the core surface of the condenser and the radiator.
INSTALLATION
CAUTION:
●
Replace the O-rings of the high-pressure pipe and the high-pressure flexible hose with new ones,
then apply compressor oil to them after installing them.
●
When pouring refrigerant, check for leaks.
Evaporator
EJS0031K
REMOVAL
1.
Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2.
Disconnect the low-pressure flexible hose and the high-pressure
pipe from the evaporator.
CAUTION:
Cap or wrap the joint of the low-pressure flexible hose and
the high-pressure pipe with a suitable tool such as a vinyl
tape to avoid the entry of air.
3.
Hold expansion valve and move it slightly upward. Push evapo-
rator toward rear of vehicle.
RJIA0080E
RJIA2344E
High-pressure flexible hose mounting bolts
Tightening torque
:7.8 - 19.6 N·m (0.8 - 2.0 kg-m, 70 - 173 in-lb)
High-pressure pipe mounting bolts
Tightening torque
:2.9 - 5.9 N·m (0.29 - 0.6 kg-m, 26- 52 in-lb)
Condenser mounting bolts
Tightening torque
:3.82 - 4.51 N·m (0.39 - 0.46 kg-m, 34 - 39 in-lb)
RJIA1720E
ATC-142
REFRIGERANT LINES
4.
Remove the drain hose and lower cover mounting screw.
5.
Swivel rear of lower case toward passenger seat to remove
lower case.
6.
Remove the intake sensor from evaporator.
7.
Slide the evaporator to backward, then remove it from the heater
& cooling unit.
INSTALLATION
CAUTION:
●
Replace the O-rings of the low-pressure flexible hose and the high-pressure pipe with new ones,
then apply compressor oil to them when installing them.
●
Mark the mounting position of the intake sensor bracket.
Expansion Valve
EJS0031L
REMOVAL
1.
Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2.
Disconnect the low-pressure flexible hose and high-pressure
pipe from the evaporator.
CAUTION:
Cap or wrap the joint of the low-pressure flexible hose and
the high-pressure pipe with a suitable tool such as a vinyl
tape to avoid the entry of air.
3.
Remove the evaporator. Refer to
.
4.
Remove the expansion valve from evaporator.
INSTALLATION
1.
Set the expansion valve to cooler grommet.
2.
Install the evaporator to heater & cooling unit.
RJIA0189E
RJIA1720E
RJIA0840E
RJIA0841E
REFRIGERANT LINES
ATC-143
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ATC
3.
Install the lower cover, then slide evaporator to forward.
4.
Install the expansion valve from engine compartment
Checking for Refrigerant Leaks
EJS0031M
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak Detector
EJS0031N
1.
Check A/C system for leaks using the UV lamp and safety goggles (J-42220) in a low sunlight area (area
without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright
green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indi-
cates an evaporator core assembly (tubes, core or expansion valve) leak.
2.
If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3.
After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiag-
nosis.
4.
Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye Injection
EJS0031O
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1.
Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52kg/cm
2
, 50
psi).
2.
Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459).
3.
Connect the injector tool to the A/C LOW PRESSURE side service fitting.
4.
Start engine and switch A/C ON.
5.
When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture
′
s operat-
ing instructions).
Expansion valve mounting bolts
Tightening torque
:2.9 - 5.0 N·m (0.30 - 0.50 kg-m, 26
- 44 in-lb)
RJIA0842E
ATC-144
REFRIGERANT LINES
6.
With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system con-
nection and proceed with the service procedures.
7.
Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
Electronic Refrigerant Leak Detector
EJS0031P
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C leak detector
or equivalent. Ensure that the instrument is calibrated and set prop-
erly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.
1.
Position probe approximately 5 mm (3/16 in) away from point to
be checked.
2.
When testing, circle each fitting completely with probe.
3.
Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
SHA705EB
SHA707EA
SHA706E
SHA708E
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