COMPRESSOR (for 2ZR-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.
Fig 1: Identifying Drain Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

The drain bolt and washer can be reused.

Standard:

(Oil capacity inside the new compressor: 90 + 15 cc (3.04 + 0.51 fl.oz.)) - (Remaining oil amount in the removed compressor) = (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), install the compressor assembly with pulley with the 2 stud bolts.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
  
  Fig 2: Identifying Compressor Assembly Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the compressor assembly with pulley with the 2 bolts and the 2 nuts.
  HINT:
  
  Tighten the bolts and the nuts in the order shown in the illustration.
  
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
3. Connect the connector.
Fig 3: Identifying Compressor Assembly With Bolts And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT 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.
  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)
CONNECT 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
  
  Fig 4: Identifying Discharge Hose Sub-Assembly Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the O-ring onto the suction hose sub-assembly.
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 )
ADJUST V-RIBBED BELT (See INSTALLATION )

Fig 5: Identifying Suction Hose Sub-Assembly Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT V-RIBBED BELT (See ON-VEHICLE INSPECTION )
INSTALL ENGINE UNDER COVER RH
CHARGE WITH REFRIGERANT (See REFRIGERANT )
WARM UP ENGINE (See REPLACEMENT )
INSPECT FOR REFRIGERANT LEAK (See ON-VEHICLE INSPECTION )