Heater & Air Conditioner: Replacement

DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
1. Turn the A/C switch on.
2. Operate the cooler compressor at an engine RPM of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.
3. Stop the engine.
4. Using SST, let the refrigerant gas out.
  SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
CHARGE REFRIGERANT
1. Using a vacuum pump, perform vacuum purging.
2. Using SST charge refrigerant, HFC-134a (R134a).
  Standard: 650 +/- 50 g (22.93 +/- 1.76 oz.)
  
  SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
NOTE: Do not start the engine before charging with refrigerant as the cooler compressor doesn't work properly without any refrigerant, which causes the compressor to overheat.

Fig 1: Identifying Refrigerant Pressure Graph
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
WARM UP ENGINE
NOTE: Warm up the engine at less than 2000 RPM for 2 minutes or more after charging with refrigerant.
INSPECT LEAKAGE OF REFRIGERANT
1. Perform in these conditions:
  - Stop the engine.
  - Secure good ventilation (the gas leak detector may not react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).
  - Repeat the test 2 or 3 times.
  - Make sure that there is some refrigerant remaining in the refrigeration system.
  - When compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)
2. Bring the gas leak detector close to the drain hose before performing the test.
  HINT:
  - After the blower motor has stopped, leave the cooling unit for more than 15 minutes.
  - Expose the gas leak detector sensor under the drain hose.
  - When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases.
  Fig 2: Inspecting Leakage Of Gas
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If such reaction is unavoidable, the vehicle must be lifted up.
3. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.
4. Disconnect the connector and leave the pressure switch for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.
5. Bring the gas leak detector close to the refrigerant lines and perform the test.

REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
1. Loosen bolt A.
2. Loosen bolt B.
3. Loosen bolt C and remove the V belt.
Fig 1: Removing Bolt A or B
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
1. Temporarily install the V belt as illustrated.
Fig 2: Installing Temperature V Belt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
1. Apply drive belt tension by turning bolt C.
  Drive belt tension:
  
  New belt: 160 to 180 lbf
  
  Used belt: 115 to 135 lbf
Fig 3: Applying Drive Belt Tension By Using Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- "New V belt" refers to a belt which has been used for less than 5 minutes on a running engine.
- "Used V belt" refers to a belt which has been used for 5 minutes or more on a running engine.
- After installing the V belt, check that it fits properly in the ribbed grooves.
Fig 4: Installing V Belt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
1. Tighten bolt A.
  Torque: 58 N.m (591 kgf.cm, 43 ft.lbf)
2. Tighten bolt B.
  Torque: 18 N.m (183 kgf.cm, 13 ft.lbf)

Fig 5: Tightening Bolt A Or Bolt B