Installation [09/2022 - ]: Procedure

ADJUST COMPRESSOR OIL (except 2UR-GSE)

When replacing the compressor with a new one:

Remove the drain bolt (washer).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Drain Bolt (Washer)

Gradually discharge the inert gas from the service valve. Then drain the following amount of oil from the new compressor before installation so that the amount of oil contained in it is the same as that in the compressor to be replaced.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Removed Compressor
*b	Amount of oil to be drained from removed compressor
*c	Amount of oil remaining in the reserve chamber (60 cc (2.03 fl.oz))

HINT:

New compressors are filled with sufficient oil for the whole air conditioning system. Therefore, it is necessary to drain oil from the new compressor to compensate for oil remaining in the condenser and cooling unit.

Standard

(The amount of compressor oil inside a new compressor and magnetic clutch: 70 (+15) cc (2.37 (+0.51) fl.oz)) - (The amount of compressor oil remaining in the removed compressor and magnetic clutch) = The amount of compressor oil to be removed when replacing the compressor and magnetic clutch

NOTE:

When A + 60 cc (2.03 fl.oz) exceeds the standard oil fill volume specified for the compressor by part number, install the compressor without adjusting the oil volume.
Example:

If A = 45 cc (1.52 fl.oz), A + 60 cc (2.03 fl.oz) = 105 cc (3.55 fl.oz). If the standard volume is 100 cc (3.38 fl.oz), install the compressor as is.
If the amount of oil remaining in the removed compressor is too low, check for oil leaks.
for HFC-134a(R134a): Make sure to use ND-OIL 8 or equivalent compressor oil.
for HFO-1234yf(R1234yf): Make sure to use ND-OIL 12 or equivalent compressor oil.

Install the drain bolt (washer).
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

If draining the oil is difficult, drain the oil using the following procedure:

Remove the suction seal cap.

Lightly shake the compressor with the suction port facing down, and drain the oil (*1).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Do not allow the pulley to come into contact with the compressor oil.

With the pulley facing down, rotate the hub as shown in the illustration 10 times at a rate of approximately once every 2 seconds (*2).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING:

If the pulley is rotated, refrigerant or oil may spray out. Thus, keep your face away from the compressor port.

Rotate the hub once as shown in the illustration while quickly turning the compressor with the pulley facing up (*3).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Perform step (*1) and drain the oil (*4).
Drain the oil by repeating steps (*2) to (*4) approximately 5 times.

ADJUST COMPRESSOR OIL (for 2UR-GSE)

When replacing the compressor assembly with pulley with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil before installation.
NOTE:
- If a new compressor assembly with pulley is installed without removing the same amount of compressor oil as is remaining in the pipes, the amount of compressor oil will be excessive. This prevents heat exchange in the refrigerant cycle and will cause the air conditioning system to malfunction.
- A certain amount of compressor oil remains in the compressor assembly with pulley during circulation and the compressor may be damaged if the amount of compressor oil is more/less than this amount. Therefore, make sure to adjust the amount of compressor oil correctly.
- If the amount of compressor oil remaining in the removed compressor assembly with pulley is excessively low, check for compressor oil leaks.
- Do not race the engine before replacing the compressor assembly with pulley.
- Make sure to use ND-OIL 12 or equivalent compressor oil.

Remove the drain bolt (seal washer) from the removed compressor assembly with pulley.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Drain Bolt (Seal Washer)

Drain the compressor oil from the oil port of the removed compressor assembly with pulley as shown in the illustration.

NOTE:

Make sure to drain the compressor oil from the oil port.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Oil Port

Turn Clockwise

Remove the drain bolt (seal washer) from the new compressor assembly with pulley.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Drain Bolt (Seal Washer)

HINT:

The drain bolt (seal washer) can be reused.

Drain the following amount of compressor oil from the oil port of the new compressor assembly with pulley as shown in the illustration.

Standard

(The amount of oil in a new compressor assembly with pulley: 70 (+15) cc (2.37 (+0.51) fl.oz)) - (The amount of oil in the removed compressor assembly with pulley) = The amount of oil to be removed from the new compressor assembly with pulley.

NOTE:

Make sure to drain the compressor oil from the oil port.
Make sure to add the compressor oil from the oil port, not from the discharge or intake port.
If a tool is used to add compressor oil to the new compressor assembly with pulley, make sure that it is free of foreign matter.
If the amount of compressor oil remaining in the removed compressor assembly with pulley cannot be estimated because the compressor was damaged and oil was discharged due to a frontal collision, etc., install a new compressor assembly with pulley without removing any oil. If the cooler condenser assembly is also replaced, do not add the specified amount of compressor oil for cooler condenser assembly replacement (40 cc (1.35 fl.oz)).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Oil Port

Turn Clockwise

Install the drain bolt (seal washer) to the new compressor assembly with pulley.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

NOTE:
Make sure that there is no damage or foreign matter on the seal washer edge.

INSTALL COMPRESSOR AND MAGNETIC CLUTCH (for 2GR-FKS)

for Type A:

Using an E8 "TORX" socket wrench, temporarily install the compressor and magnetic clutch with the stud bolt.
Tighten the stud bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Install the compressor and magnetic clutch with the 3 bolts and nut.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt

Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)

Nut

Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)

HINT:

Tighten the bolts and nut in the order shown in the illustration.

for Type B:

Using an E8 "TORX" socket wrench, temporarily install the compressor and magnetic clutch with the stud bolt.
Tighten the stud bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Install the compressor and magnetic clutch with the 3 bolts and nut.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt

Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)

Nut

Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)

HINT:

Tighten the bolts and nut in the order shown in the illustration.

Engage the clamp.
Connect the 2 connectors.

INSTALL COMPRESSOR AND MAGNETIC CLUTCH (for 8AR-FTS)

Using an E8 "TORX" socket wrench, temporarily install the compressor and magnetic clutch with the 2 stud bolts.

Tighten the 2 stud bolts.

Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Install the compressor and magnetic clutch with the 2 bolts and 2 nuts.
Bolt

Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)

Nut

Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)

HINT:

Tighten the bolts and nuts in the order shown in the illustration.
Engage the clamp.
Connect the 2 connectors.

INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (for 2UR-GSE)

Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

	Bolt
	Nut

Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)

HINT:

Tighten the bolts and nuts in the order shown in the illustration.

Connect the wire harness clamp bracket with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Connect the connector.

CONNECT SUCTION HOSE (for 2GR-FKS)
1. Remove the vinyl tape from the suction hose and compressor and magnetic clutch.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.
  Compressor Oil
  
  ND-OIL 12 or equivalent
3. Install the O-ring to the suction hose.
4. Connect the suction hose to the compressor and magnetic clutch with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

CONNECT SUCTION HOSE (for 8AR-FTS)

Remove the vinyl tape from the suction hose and compressor and magnetic clutch.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

Refrigerant	Compressor Oil
HFC-134a (R134a)	ND-OIL 8 or equivalent
HFO-1234yf (R1234yf)	ND-OIL 12 or equivalent

Install the O-ring to the suction hose.
Connect the suction hose to the compressor and magnetic clutch with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

CONNECT SUCTION HOSE (for 2UR-GSE)
1. Remove the vinyl tape from the suction hose and compressor assembly with pulley.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose.
  Compressor Oil
  
  ND-OIL 12 or equivalent
3. Install the O-ring to the suction hose.
4. Connect the suction hose to the compressor assembly with pulley with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (for 2GR-FKS)
1. Remove the vinyl tape from the No. 1 cooler refrigerant discharge hose and compressor and magnetic clutch.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.
  Compressor Oil
  
  ND-OIL 12 or equivalent
3. Install the O-ring to the No. 1 cooler refrigerant discharge hose.
4. Connect the No. 1 cooler refrigerant discharge hose to the compressor and magnetic clutch with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (for 8AR-FTS)

Remove the vinyl tape from the No. 1 cooler refrigerant discharge hose and compressor and magnetic clutch.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

Refrigerant	Compressor Oil
HFC-134a (R134a)	ND-OIL 8 or equivalent
HFO-1234yf (R1234yf)	ND-OIL 12 or equivalent

Install the O-ring to the No. 1 cooler refrigerant discharge hose.
Connect the No. 1 cooler refrigerant discharge hose to the compressor and magnetic clutch with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (for 2UR-GSE)
1. Remove the vinyl tape from the No. 1 cooler refrigerant discharge hose and compressor assembly with pulley.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 1 cooler refrigerant discharge hose.
  Compressor Oil
  
  ND-OIL 12 or equivalent
3. Install the O-ring to the No. 1 cooler refrigerant discharge hose.
4. Connect the No. 1 cooler refrigerant discharge hose to the compressor assembly with pulley with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
INSTALL FAN AND GENERATOR V BELT
for 2GR-FKS:

Refer to INSTALLATION [10/2017 - ]

for 8AR-FTS:

Refer to INSTALLATION [08/2015 - ]

for 2UR-GSE:

Refer to INSTALLATION [11/2021 - ]
INSTALL REAR ENGINE UNDER COVER LH
for 2GR-FKS:

Refer to PROCEDURE - Step 101

for 8AR-FTS:

Refer to PROCEDURE - Step 75

for 2UR-GSE:

Refer to PROCEDURE - Step 65
INSTALL ENGINE UNDER COVER
for 2GR-FKS:

Refer to PROCEDURE - Step 103

for 8AR-FTS:

Refer to PROCEDURE - Step 78

for 2UR-GSE:

Refer to PROCEDURE - Step 89
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFO-1234yf(R1234yf))
Refer to PROCEDURE - Step 2
WARM UP ENGINE (for HFO-1234yf(R1234yf))
Refer to PROCEDURE - Step 3
INSPECT FOR REFRIGERANT LEAK (for HFO-1234yf(R1234yf))
Refer to PROCEDURE - Step 4
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFC-134a(R134a))
Refer to PROCEDURE - Step 2
WARM UP ENGINE (for HFC-134a(R134a))
Refer to PROCEDURE - Step 3
INSPECT FOR REFRIGERANT LEAK (for HFC-134a(R134a))
Refer to PROCEDURE - Step 4