COMPRESSOR (for 1AR-FE): Installation

ADJUST COMPRESSOR OIL LEVEL
1. When replacing the cooler compressor assembly with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil from the vents indicated by the arrows in the illustration before installation.
  HINT:
  
  The drain bolt and washer can be reused.
  
  Fig 1: Locating Service Valve Vents
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard (w/o Rear Air Conditioning System): (Oil capacity inside the new compressor assembly with pulley: 130 + 15 cc (4.4 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor assembly with pulley) = (Oil amount to be removed from the new compressor when replacing)
  
  Standard (w/ Rear Air Conditioning System):
  
  (Oil capacity inside the new compressor assembly with pulley: 225 + 15 cc (7.6 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor assembly with pulley) = (Oil amount to be removed from the new compressor when replacing)
  NOTE:
  - If a new compressor is installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be excessive. This prevents heat exchange in the refrigerant cycle and causes refrigeration system failure.
  - If the volume of oil remaining in the removed compressor is too small, check for oil leaks.
  - Be sure to use ND-OIL 8 or equivalent for compressor oil.
INSTALL COMPRESSOR ASSEMBLY WITH PULLEY
1. Using a "TORX" socket wrench (E8), temporarily install the compressor assembly with pulley with the 2 stud bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 2: Identifying Stud Bolts Of Compressor Assembly With Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the compressor assembly with pulley with the 2 bolts and the 2 nuts.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  HINT:
  
  Tighten the bolts and the nuts in the order shown in the illustration.
3. Connect the connector.
INSTALL DISCHARGE HOSE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the hose.
2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.
  
  Fig 3: Identifying Compressor Assembly With Pulley Bolts And Nuts Tighten Order
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Compressor oil:
  
  ND-OIL 8 or equivalent
3. Install the O-ring onto the discharge hose sub-assembly.
4. Install the discharge hose sub-assembly onto the compressor assembly with pulley with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
INSTALL SUCTION HOSE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the hose.
2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.
  Compressor oil:
  
  ND-OIL 8 or equivalent
3. Install the O-ring onto the suction hose sub-assembly.
  
  Fig 4: Identifying Discharge Hose Sub-Assembly And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the suction hose sub-assembly onto the compressor assembly with pulley with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
INSTALL V-RIBBED BELT (See INSTALLATION )
INSTALL FRONT FENDER APRON SEAL RH (See INSTALLATION )
INSTALL FRONT FENDER LINER RH (See INSTALLATION )
INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH (See INSTALLATION )

Fig 5: Identifying Suction Hose Sub-Assembly And Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 ENGINE UNDER COVER
INSTALL FRONT WHEEL RH (See INSTALLATION )
CHARGE WITH REFRIGERANT (See REFRIGERANT LINE )
WARM UP ENGINE (See REFRIGERANT LINE )
INSPECT FOR REFRIGERANT LEAK (See REFRIGERANT LINE )