COMPRESSOR AND PULLEY (for 2GR-FSE 4WD): Installation

ADJUST COMPRESSOR OIL
1. When replacing the compressor with a new one, after gradually discharging the refrigerant gas from the service valve, drain the following volume of oil from the new compressor before installation.
  Standard:
  
  (Oil capacity inside a new compressor: 130 + 15 cc (4.6 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed from the new compressor when replacing it.
  NOTE:
  - When checking the compressor oil level, observe the precautions in the cooler removal/installation.
  - If a new compressor is 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.
  - If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
  - Be sure to use ND-OIL 8 for compressor oil.
INSTALL COMPRESSOR ASSEMBLY
1. Using an E8 "Torx" socket, install the compressor with the stud bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 1: Identifying Compressor Assembly Stud Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the compressor with the 2 bolts and nut.
  HINT:
  
  Temporarily install the bolts and nut.
Fig 2: Identifying Compressor Assembly Bolts And Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
1. Install a new oil filter bracket gasket and the oil filter bracket with the 2 nuts and bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 3: Identifying Oil Filter Bracket Sub-Assembly Nuts And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the wire harness to connect the connector and attach the 2 clamps.
Fig 4: Identifying Wire Harness Clamps And Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER BRACKET
1. Install the oil filter bracket with the bolt and nut.
  Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
  
  HINT:
  
  Temporarily install the bolt.
Fig 5: Identifying Oil Filter Bracket Bolt And Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TIGHTEN COMPRESSOR ASSEMBLY
1. Install the compressor with the bolts and nut.
  Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
  
  NOTE: Tighten the bolts in the order shown in the illustration to install the compressor.
Fig 6: Locating Compressor Assembly Bolts And Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DISCHARGE HOSE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the discharge hose.
2. 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
3. Install the O-ring on the discharge hose.
4. Install the discharge hose on the compressor with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 7 in.*lbf)
Fig 7: Identifying Discharge Hose Sub-Assembly Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE
1. Remove the attached vinyl tape from the suction hose.
2. 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
3. Install the O-ring on the suction hose.
  
  Fig 8: Identifying No. 1 Cooler Refrigerant Suction Hose Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the suction hose on the compressor with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 7 in.*lbf)
INSTALL ENGINE UNDER COVER (See INSTALLATION )
INSTALL FAN AND GENERATOR V BELT (See INSTALLATION )
INSTALL V-BANK COVER (See INSTALLATION )
INSTALL NO. 1 AIR CLEANER INLET (See INSTALLATION )
INSTALL ENGINE ROOM SIDE COVER LH (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CHARGE REFRIGERANT (See REPLACEMENT )
INSTALL COOL AIR INTAKE DUCT SEAL (See INSTALLATION )
WARM UP ENGINE (See REPLACEMENT )
CHECK FOR LEAKAGE OF REFRIGERANT (See REPLACEMENT )
PERFORM INITIALIZATION
1. Perform initialization (see INITIALIZATION ).
  NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.