Installation [10/2015 - ]: Procedure

1. 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 8 or equivalent compressor oil.
2. Remove the drain bolt (seal washer) from the removed compressor assembly with pulley.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. 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

   *a

   Oil Port

   *b

   Turn Clockwise

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   The drain bolt (seal washer) can be reused.

5. 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 the 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

   *a

   Oil Port

   *b

   Turn Clockwise

6. 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.

1. 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) 

2. Install the compressor assembly with pulley with the 2 bolts and 2 nuts.
   Fig 1: Compressor Assembly With Pulley Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   HINT: 

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

3. Connect the wire harness clamp bracket with the bolt.

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

4. Connect the connector.

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 8 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) 

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 8 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) 

1. Install the front stabilizer bar to the vehicle so that the identification mark is positioned on the right side of the vehicle.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Identification Mark
   	Front of the Vehicle
   	RH Side

2. Connect the front stabilizer link sub-assembly LH to the front stabilizer bar with the nut.

   Torque: 84 N*m (857 kgf*cm, 62 ft.*lbf) 

   HINT: 

   • If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud bolt.
   • Use the same procedure for the RH side and LH side.

Refer to PROCEDURE - Step 5 [10/2015 - 05/2018], or Refer to PROCEDURE - Step 5 [05/2018 - ]

HINT: 

Use the same procedure as for the LH side.

Refer to PROCEDURE - Step 72 [10/2015 - 05/2018], or Refer to PROCEDURE - Step 73 [05/2018 - ]

HINT: 

Use the same procedure as for the LH side.

Refer to PROCEDURE - Step 96 [10/2015 - 05/2018], or Refer to PROCEDURE - Step 97 [05/2018 - ]

Refer to INSTALLATION [10/2015 - ]

See step  2

See step  3

See step  4

Refer to ADJUSTMENT [10/2015 - ]