Installation [12/2017 - 11/2021]: 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.
   • Make sure to use ND-OIL 12 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: 100 to 115 cc (3.38 to 3.89 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, install the 2 stud bolts.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt
   	Nut

   NOTE:

   Tighten the 2 nuts and 2 bolts in the order shown in the illustration.

   Nut, Bolt 

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

3. Connect the connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the vinyl tape from the suction hose sub-assembly and connecting part of the compressor assembly with pulley.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

   Compressor Oil

   ND-OIL 12 or equivalent

3. Install the O-ring to the suction hose sub-assembly.
   NOTE:

   Keep the O-ring and O-ring fitting surface free of foreign matter.

4. Connect the suction hose sub-assembly to the compressor assembly with pulley with the bolt.

   Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   • Do not apply excessive force to the suction hose sub-assembly.
   • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

1. Remove the vinyl tape from the discharge hose sub-assembly and connecting part of the compressor assembly with pulley.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

   Compressor Oil

   ND-OIL 12 or equivalent

3. Install the O-ring to the discharge hose sub-assembly.
   NOTE:

   Keep the O-ring and O-ring fitting surface free of foreign matter.

4. Connect the discharge hose sub-assembly to the compressor assembly with pulley with the bolt.

   Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

   NOTE:

   • Do not apply excessive force to the discharge hose sub-assembly.
   • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 3

1. Install the air cleaner support bracket assembly with the 2 bolts.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Attach the clamp to install the No. 13 connector holder to the air cleaner support bracket assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Clamp
   *b	Guide

2. Connect the connector.

1. Remove the vinyl tape from the suction hose sub-assembly and air conditioning tube and accessory assembly.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly.

   Compressor Oil

   ND-OIL 12 or equivalent

3. Install the O-ring to the suction hose sub-assembly.
   NOTE:

   Keep the O-ring and O-ring fitting surface free of foreign matter.

4. Connect the suction hose sub-assembly to the air conditioning tube and accessory assembly with the nut.

   Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

   NOTE:

   • Do not apply excessive force to the suction hose sub-assembly and air conditioning tube and accessory assembly.
   • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 128 [12/2017 - 09/2018] , or refer to PROCEDURE - Step 128 [09/2018 - 10/2020] , or refer to PROCEDURE - Step 128 [10/2020 - 10/2023]

Refer to PROCEDURE - Step 127 [12/2017 - 09/2018] , or refer to PROCEDURE - Step 127 [09/2018 - 10/2020] , or refer to PROCEDURE - Step 127 [10/2020 - 10/2023]

1. Install the radiator support to crossmember brace sub-assembly RH with the 2 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

1. Install the radiator support to crossmember brace sub-assembly LH with the 2 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 5

Refer to PROCEDURE - Step 9

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 7

Refer to PROCEDURE - Step 17

Refer to PROCEDURE - Step 17

Refer to PROCEDURE - Step 8

Refer to PROCEDURE - Step 9

Refer to PROCEDURE - Step 10

Refer to PROCEDURE - Step 192 [12/2017 - 09/2018] , or refer to PROCEDURE - Step 192 [09/2018 - 10/2020] , or refer to PROCEDURE - Step 193 [10/2020 - 10/2023]