Installation [12/2013 - ]: Procedure

1. When replacing the compressor assembly with pulley with a new one, gradually discharge the inert gas (helium) from the service valve, and drain the following amount of oil before installation.
   NOTE:

   • If a new compressor assembly with pulley is installed without removing the same amount of compressor oil as is remaining in the pipes, the amount of compressor oil will be excessive. This prevents heat exchange in the refrigerant cycle and will cause a refrigeration failure.
   • A certain amount of compressor oil remains in the compressor assembly with pulley during circulation and the compressor may be damaged if the amount of compressor oil is more/less than this amount. Therefore, make sure to adjust the amount of compressor oil correctly.
   • If the amount of compressor oil remaining in the removed compressor assembly with pulley is too low, check for compressor oil leakage.
   • Do not race the engine before replacing the compressor assembly with pulley.
   • Make sure to use ND-OIL 8 or equivalent compressor oil.
2. Remove the drain bolt (seal washer) from the removed compressor assembly with pulley.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Drain Bolt (Seal Washer)

3. Drain the compressor oil from the oil port of the removed compressor assembly with pulley as shown in the illustration.
   NOTE:

   Make sure to drain the compressor oil from the oil port.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Oil Port

   *b

   Turn Clockwise

4. Remove the drain bolt (seal washer) from the new compressor assembly with pulley.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Drain Bolt (Seal Washer)

   HINT: 

   The drain bolt (seal washer) can be reused.

5. Drain the following amount of compressor oil from the oil port of the new compressor assembly with pulley as shown in the illustration.

   Standard

   (The amount of oil in a new compressor assembly with pulley: 120 cc (4.06 fl.oz)) - (The amount of oil in the removed compressor assembly with pulley) = The amount of oil to be removed from the new compressor assembly with pulley.

   NOTE:

   • Make sure to drain the compressor oil from the oil port.
   • Make sure to add the compressor oil from the oil port, not from the discharge or intake port.
   • If a tool is used to add compressor oil to the new compressor assembly with pulley, make sure that it is free of foreign matter.
   • If the amount of compressor oil remaining in the removed compressor assembly with pulley cannot be estimated because the compressor was damaged and oil was discharged due to a frontal collision, etc., install the new compressor assembly with pulley without removing any oil. If the cooler condenser assembly is also replaced, do not add the specified amount of compressor oil for cooler condenser assembly replacement (40 cc (1.35 fl.oz)).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Oil Port

   *b

   Turn Clockwise

6. Install the drain bolt (seal washer) to the new compressor assembly with pulley.

   Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

   NOTE:

   Make sure that there is no damage or foreign matter on the seal washer edge.

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

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

2. Install the compressor assembly with pulley with the 2 bolts and 2 nuts.
   Fig 1: Tightening Sequence Of Compressor Assembly With Pulley

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt
   	Nut

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

   HINT: 

   Tighten the bolts and nuts in the order shown in the illustration to install the compressor assembly with pulley.

3. Install the bolt.
4. Connect the connector.

1. Remove the vinyl tape from the discharge hose sub-assembly.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the discharge hose sub-assembly.

   Compressor Oil

   ND-OIL 8 or equivalent

3. Install the O-ring to the discharge hose sub-assembly.
4. Install the discharge hose sub-assembly to the compressor assembly with pulley with the bolt.

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

1. Remove the vinyl tape from the suction hose sub-assembly.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

   Compressor Oil

   ND-OIL 8 or equivalent

3. Install the O-ring to the suction hose sub-assembly.
4. Install the suction hose sub-assembly to the compressor assembly with pulley with the bolt.

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

Refer to INSTALLATION [12/2013 - ]

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 4

Refer to PROCEDURE - Step 81 , or refer to PROCEDURE - Step 81