Installation [06/2018 - ]: Procedure

ADJUST COMPRESSOR OIL

When replacing the compressor assembly with magnetic clutch with a new one:

Remove the drain bolt (seal washer) from a new compressor assembly with magnetic clutch.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Drain Bolt (Seal Washer)

Gradually discharge the inert gas from the service valve of the new compressor assembly with magnetic clutch. 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.

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard

(The amount of compressor oil inside a new compressor assembly with magnetic clutch: 70 (+15) cc (2.37 (+0.51) fl.oz)) - (The amount of compressor oil remaining in the removed compressor assembly with magnetic clutch) = The amount of compressor oil to be removed when replacing the compressor assembly with 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 70 (+15) cc (2.37 (+0.51) fl.oz)), install the compressor as is.
If the amount of compressor oil remaining in the removed compressor assembly with magnetic clutch is excessively low, check for compressor oil leaks.
Make sure to use ND-OIL 12 or equivalent compressor oil.

Install the drain bolt (seal 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 assembly with magnetic clutch 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 pulley as shown in the illustration 10 times at a rate of approximately once every 2 seconds (*2).

WARNING:

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Rotate the pulley once as shown in the illustration while quickly turning the compressor 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.

INSTALL COMPRESSOR ASSEMBLY WITH MAGNETIC CLUTCH

for Type A:

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

Install the compressor assembly with magnetic clutch and bracket with the 2 bolts and 2 nuts.

Fig 1: Compressor Assembly (for 2GR-FKS) With Magnetic Clutch Bolts And Nuts Tightening Sequence (for Type A:)

*a	Bracket
	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.

for Type B:

Install the compressor assembly with magnetic clutch and bracket with the 4 bolts.

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

HINT:

Tighten the bolts in the order shown in the illustration.

Fig 2: Compressor Assembly (for 2GR-FKS) With Magnetic Clutch And Bracket Bolts And Nuts Tightening Sequence (for Type B:)

Bracket

Engage each clamp.
Connect each connector.

CONNECT SUCTION HOSE
1. Remove the vinyl tape from the suction hose.
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.
  NOTE:
  Keep the O-rings and O-ring fitting surfaces free from foreign matter.
4. Connect the suction hose to the compressor assembly with magnetic clutch with the bolt.
  Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf)
CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
1. Remove the vinyl tape from the No. 1 cooler refrigerant discharge hose.
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.
  NOTE:
  Keep the O-rings and O-ring fitting surfaces free from foreign matter.
4. Connect the No. 1 cooler refrigerant discharge hose to the compressor assembly with magnetic clutch with the bolt.
  Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf)
INSTALL RADIATOR ASSEMBLY
Refer to INSTALLATION [06/2018 - ]
INSTALL V-RIBBED BELT
Refer to INSTALLATION [06/2018 - ]
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT
Refer to PROCEDURE - Step 2
WARM UP ENGINE
Refer to PROCEDURE - Step 3
INSPECT FOR REFRIGERANT LEAK
Refer to PROCEDURE - Step 5