COMPRESSOR AND PULLEY (for 2AZ-FE): Installation

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

ADJUST COMPRESSOR OIL
1. When replacing the compressor and magnetic clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation.
  Standard:
  
  (Oil capacity inside the new compressor and magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing)
  NOTE:
  - When checking the compressor oil level, observe the precautions on the cooler removal/installation.
  - If a new compressor and magnetic clutch is installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure.
  - If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage.
  - Be sure to use ND-OIL 8 or equivalent for compressor oil.
INSTALL COOLER COMPRESSOR ASSEMBLY
1. w/o Stud Bolt:
  Install the cooler compressor with the 4 bolts.
  
  Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
  
  NOTE: Tighten the bolts in the order shown in the illustration to install the cooler compressor.
2. w/Stud Bolt:
  Install the cooler compressor with the 3 bolts and nut.
  
  Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
  
  NOTE: Tighten the bolts in the order shown in the illustration to install the cooler compressor.
  
  Fig 1: Installing Cooler Compressor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the connector.
INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
1. Remove the attached vinyl tape from the hose.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.
  Compressor oil:
  
  ND-OIL 8 or equivalent
3. Install the O-ring on the cooler refrigerant discharge hose.
4. Install the cooler refrigerant discharge hose on the cooler compressor with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
  
  Fig 2: Locating Cooler Refrigerant Discharge Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE
1. Remove the attached vinyl tape from the hose.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.
  Compressor oil:
  
  ND-OIL 8 or equivalent
3. Install the O-ring on the cooler refrigerant suction hose.
4. Install the cooler refrigerant suction hose on the cooler compressor with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
  
  Fig 3: Locating Cooler Refrigerant Suction Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FAN AND GENERATOR V BELT (See INSTALLATION )
INSTALL NO. 1 ENGINE UNDER COVER
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CHARGE REFRIGERANT (See REPLACEMENT )
WARM UP ENGINE (See REPLACEMENT )
INSPECT FOR REFRIGERANT LEAK (See REPLACEMENT )