With Zexel Compressor

NOTES:
- A/C system components identified with an * must only be serviced or replaced after discharging refrigerant system.
- A/C system components not identified with an * can be serviced or replaced without discharging refrigerant system.
- Discharging refrigerant system, A/C System, Discharging
- A/C system cooling performance test, Testing and Inspection
- Refrigerant system pressure test, Testing and Inspection
- A/C system components, engine compartment, Locations
- Zexel A/C compressors are installed from start of production. During m.y. 1996, Nippondenso compressors are installed as a running change
- Replacement A/C compressors are filled with 250 cc (8.5 fl oz) of A/C refrigerant (PAG) oil. This is the total A/C refrigerant system oil capacity
- Do Not top-off a charged refrigerant system. Instead, discharge, evacuate and recharge system.

NOTE: A/C system components identified with an * must only be serviced or replaced after discharging refrigerant system.

1- Compressor*
- Zexel or Nippondenso, removing/installing, Compressor HVAC
- Removing/installing ribbed drive belt see engine.
- O-ring:
Low pressure connection:
17.2 mm inside diameter
1.8 mm thickness
High pressure connection:
14.0 mm inside diameter
1.8 mm thickness

- Torque:
Low pressure connection:
40 Nm (29.5 ft lb)
High pressure connection:
30 Nm (22.1 ft lb)

NOTES:
- Zexel and Nippondenso compressor ribbed drive belts are different Always refer to recent parts information.
- Mark travel direction of ribbed drive belt before removing. Reversing direction may cause belt damage.
- If a new A/C compressor is installed, or if oil was added to compressor, manually rotate compressor 10 times before operating the system to prevent compressor damage.

2- A/C Compressor Speed Sensor* (G111), Zexel Compressor Only
- Removing/installing,
- O-ring seal*:
15.5 mm inside diameter
1.5 mm thickness

CAUTION: Refrigerant system must be discharged and compressor removed prior to removal or replacement of G111.

3- A/C Clutch (N25)
- Removing/installing Compressor Clutch
4- Oil drain plug*

NOTES:
- Remove only with compressor removed from vehicle
- Use to drain or add PAG refrigerant oil, or to check the amount of oil in the compressor

Zexel compressor:
- O-ring:
7.8 mm inside diameter
1.9 mm thickness
- Torque: 10 Nm (7 ft lb)

Nippondenso compressor:
- Installed with sealing ring instead of O-ring
- Always replace sealing ring
- Torque: 10 Nm (7 ft lb)

5- Pressure Relief Valve*
- O-ring:
8.8 mm inside diameter
1.9 mm thickness
- Torque: 10 Nm (7.4 ft lb)

CAUTION: Refrigerant system must be discharged and compressor removed prior to removal of oil drain plug and pressure relief valve. Use drain plug to drain/add oil to compressor and to check amount of oil in compressor.

6- Connection with Schrader valve*
- For A/C refrigerant high pressure switch (F23/F118)
7- A/C refrigerant high pressure switch (F23/F118)
- Both switch functions are incorporated into a single housing
- O-ring:
7.6 mm inside diameter
1.8 mm thickness
- Torque: 5 Nm (44 in. lb)
8- Cap with seal
- Always re-install after using service valve
9- Service valve (high pressure)
- Installed on condenser inlet line
- Used for checking system pressure, discharging, evacuating and recharging system
10- Condenser*
- O-ring, inlet:
14.0 mm inside diameter
1.8 mm thickness
- O-ring, outlet:
7.6 mm inside diameter
1.8 mm thickness
- Torque: Inlet: 30 Nm (22.1 ft lb)
Outlet: 15 Nm (11.0 ft lb)
11- Coupling for restrictor*
- Located on evaporator inlet line
- O-ring:
10.8 mm inside diameter
1.8 mm thickness
- Torque: 15 Nm (11.O ft lb)
12- Restrictor*
- O-ring:
7.5 mm inside diameter
1.5 mm thickness
- Removing/installing
13- Evaporator*
- Removing/installing evaporator refrigerant lines Hose/Line HVAC
- Removing/installing evaporator, evaporator housing, assembly [1][2]Evaporator Case, Evaporator Core
- O-ring, inlet:
10.8 mm inside diameter
1.8 mm thickness
- O-ring, outlet:
17.2 mm inside diameter
1.8 mm thickness
- Torque (evaporator line retaining bracket): 15 Nm (11.0 ft lb)
14- A/C refrigerant low pressure switch (F73)
- O-ring:
7.6 mm inside diameter
1.8 mm thickness
- Torque: 5 Nm (44 in. lb)
15- Connection with Schrader valve*
- For A/C refrigerant low pressure switch (F73)
16- Accumulator*
- Removing/installing Accumulator HVAC
- O-ring seal inlet:
17.2 mm inside diameter
1.8 mm thickness
- O-ring seal outlet:
17.2 mm inside diameter
1.8 mm thickness
- Torque: Inlet: 40 Nm (29.5 ft lb)
Outlet: 40 Nm (29.5 ft lb)