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Installation [12/2017 - 08/2019]: Procedure

  1. ADJUST COMPRESSOR OIL 
    1. When replacing the compressor and magnetic clutch with a new one:
      1. Remove the drain bolt (seal washer) from a new compressor and magnetic clutch.
        GTY647803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Drain Bolt (Seal Washer)
      2. Gradually discharge the inert gas from the service valve of the new compressor and 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.

        GTY452636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Removed Compressor
        *b Amount of oil to be drained from removed compressor and magnetic clutch
        *c Amount of oil remaining in the reserve chamber (60 cc (2.03 fl.oz))

        Standard (w/o Rear Air Conditioning System)

        (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.

        Standard (w/ Rear Air Conditioning System)

        (The amount of compressor oil inside a new compressor and magnetic clutch: 120 (+15) cc (4.06 (+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 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 and magnetic clutch is excessively low, check for compressor oil leaks.
        • Make sure to use ND-OIL 8 or equivalent compressor oil.
      3. Install the drain bolt (seal washer).

        Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

    2. If draining the oil is difficult, drain the oil using the following procedure:
      1. Remove the suction seal cap.
      2. Lightly shake the compressor and magnetic clutch with the suction port facing down, and drain the oil (*1).
        GTY682024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

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

    3. 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.

      GTY655743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Rotate the pulley once as shown in the illustration while quickly turning the compressor up (*3).
      GTY655744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Perform step (*1) and drain the oil (*4).
    6. Drain the oil by repeating steps (*2) to (*4) approximately 5 times.
  2. INSTALL COMPRESSOR AND MAGNETIC CLUTCH 
    1. for Type A:
      1. Using an E 8 "TORX" socket wrench, temporarily install the compressor and magnetic clutch with the 2 stud bolts.

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

      2. Install the compressor and magnetic clutch and bracket with the 2 bolts and 2 nuts.
        GTY663699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *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 to install the compressor and magnetic clutch.

    2. for Type B:
      1. Install the compressor and 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 to install the compressor and magnetic clutch.

        Fig 1: Compressor And Magnetic Clutch Tightening Sequence [12/2017 - 08/2019]
        GTY619181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Bracket
    3. Engage each clamp.
    4. Connect each connector.
  3. CONNECT SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the suction hose sub-assembly.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.
    4. Install the suction hose sub-assembly to the compressor and magnetic clutch with the bolt.

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

  4. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the discharge hose sub-assembly.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the discharge hose sub-assembly.

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Install the O-ring to the discharge hose sub-assembly.
    4. Install the discharge hose sub-assembly to the compressor and magnetic clutch with the bolt.

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

  5. INSTALL RADIATOR ASSEMBLY 

    Refer to INSTALLATION [09/2015 - ]

  6. INSTALL V-RIBBED BELT 

    Refer to INSTALLATION [09/2015 - ]

  7. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  8. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  9. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

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