Installation [05/2023 - ]: Procedure

1. When replacing the compressor with motor assembly with a new one, drain the following amount of oil from the position shown by the arrow in the illustration before installing the new compressor with motor assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Discharge Port
   *b	Intake Port

   Standard

   (Oil capacity inside the new compressor with motor assembly: 120 to 135 cc (4.06 to 4.56 fl.oz)) - (Remaining oil amount in the removed compressor with motor assembly) - 65 cc (2.20 fl.oz) = (Oil amount to be removed from the new compressor)

   NOTE:

   • If a new compressor with motor assembly is installed without removing some oil, there will be too much oil in the system due to the oil remaining in the pipes of the vehicle. Excessive oil in the system prevents heat exchange in the refrigeration cycle and causes ineffective cooling.
   • If the amount of oil remaining in the old compressor with motor assembly is too small, check the air conditioning system for oil leaks.
   • Be sure to use ND-OIL 11 or equivalent compressor oil. If any compressor oil other than ND-OIL 11 is used, compressor with motor assembly insulation performance may decrease, resulting in leakage of electric power.
   • Make sure to drain compressor oil from the intake port.
   • Make sure to add compressor oil from the intake port.
   • If the amount of oil from the removed compressor with motor assembly plus an additional 65 cc (2.20 fl.oz) is then greater than the amount of oil in a new compressor with motor assembly, do not drain the compressor oil from the new compressor with motor assembly.
   • When it is not possible to confirm the amount of oil in the system such as when compressor oil is spilt due to damage caused by a vehicle collision, etc., install a new compressor without draining any oil. If also replacing the cooler condenser assembly, do not add the supplied oil (40 cc (1.35 fl.oz)).

1. Using an E8 "TORX" socket wrench, temporarily install the compressor with motor assembly with the 2 stud bolts.

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

   HINT: 

   Insert bolt (E) into the compressor with motor assembly beforehand.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Stud Bolt
   	bolt (E)

2. Install the compressor with motor assembly with the 2 nuts, bolt (D) and bolt (E).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Nut
   	Bolt (D)
   	Bolt (E)

   NOTE:

   Tighten the 2 nuts, bolt (D) and bolt (E) in the order shown in the illustration.

   Nut, Bolt (D), Bolt (E) 

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

3. Remove the vinyl tape wrapped around the connector (B).
4. Connect the connector (B) and slide the green-colored lock as shown in the illustration to lock it securely.
   WARNING:

   Make sure to wear insulating gloves.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Stopper
   *b	Green-colored Lock
   	Bolt (C)
   	Connector (B)

   NOTE:

   Make sure that the connector is connected securely.

5. Install the wiring harness clamp bracket (bolt (C) fastening side) with the bolt (C).
   NOTE:

   Install with a stopper on upper area of the compressor with motor assembly.

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

6. Install the wiring harness clamp bracket (bolt (B) fastening side) with the bolt (B).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Rib
   	Bolt (A)
   	Connector (A)
   	bolt (B)

   Torque: 17.5 N.m (178 kgf/cm, 13 ft.lbf) 

7. Install the wiring harness clamp bracket (bolt (A) fastening side) with the bolt (A).
   NOTE:

   Install by attaching the rib on the surface of the compressor with motor assembly as shown in the illustration.

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

8. Connect the connector (A).

1. Remove the vinyl tape from the suction hose sub-assembly, suction tube sub-assembly B and connecting part of the compressor with motor assembly.
2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the suction tube sub-assembly B and the fitting surface of the compressor with motor assembly.

   Compressor Oil

   ND-OIL 11 or equivalent

   NOTE:

   Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

3. Install the 2 O-rings 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 with motor assembly with the bolt.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt
   	Nut

   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)
5. Connect the suction hose sub-assembly to the suction tube sub-assembly B 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 suction tube sub-assembly B.
   • 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 with motor assembly.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

   Compressor Oil

   ND-OIL 11 or equivalent

   NOTE:

   Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

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. Insert a torque wrench from the rear of the compressor with motor assembly as shown in the illustration and connect the discharge hose sub-assembly to the compressor with motor assembly 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 discharge hose sub-assembly.
   • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

Refer to PROCEDURE - Step 114

Refer to PROCEDURE - Step 115

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 INSTALLATION [05/2023 - ]

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 13

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 4

Refer to PROCEDURE - Step 118

HINT: 

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Refer to AUTOMATIC LEARNING CHART [05/2023 - ]

Refer to DTC CHECK / CLEAR [04/2020 - ]

Refer to OPERATION CHECK [04/2020 - ]